Heating, Ventilation, and Air Conditioning (Flushing): Repair Instructions

Make

Vauxhall

Model

Astra J

Section

Heating, Ventilation, and Air Conditioning › Repair Instructions › Flushing

HVACFlushing

Flushing Special Tools •  BO-42220   Universal 12V Leak Detection Lamp •  GE-41447   R-134A A/C Tracer Dye Box of 24 •  GE-45268   A/C Flush Adapter Kit For equivalent regional tools, refer to Special Tools . Note:  Flushing with the ACR 2000 is not intended to remove metal from the A/C system. Flushing is intended to remove the following: •  Contaminated polyalkylene glycol (PAG) oil •  Desiccant, following a desiccant bag failure •  Overcharge of PAG oil •  Refrigerant contamination Forward Flushing Setup            Note:  Forward flow refrigerant flushing is recommended for contaminated refrigerant or PAG oil. Note:  Inspect and lubricate GE-45268   adapter kit fitting O-rings. Refer to Air Conditioning O-Ring Seal Replacement . 1. Install both GE-45268-9   fitting O-rings onto the GE-45268-10   adapter . 2. Install the GE-45268-8   fitting O-ring onto the suction side of the GE-45268-10   adapter . 3. Install the GE-45268-7   fitting O-ring onto the discharge side of the GE-45268-10   adapter . Reverse Flushing Setup Note:  •  Reverse flow refrigerant flush is recommended for desiccant bag failure. Replace the condenser/receiver dehydrator assembly when the A/C flush is complete and perform the following procedure: •  Inspect and lubricate the GE-45268   adapter kit fitting O-rings. Refer to Air Conditioning O-Ring Seal Replacement . 1. Install both GE-45268-9   fitting O-rings onto the GE-45268-10   adapter . 2. Install the GE-45268-8   fitting O-ring onto the suction side of the GE-45268-10   adapter . 3. Install the GE-45268-7   fitting O-ring onto the discharge side of the GE-45268-10   adapter . Flush Procedure Note:  Warmer engine or ambient temperatures decreases refrigerant recovery time during the A/C flush procedure. 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . 2. Remove the thermal expansion valve (TXV). Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement . 3. Install the TXV stud onto the GE-45268-115   adapter . 4. Install new sealing washers onto the evaporator core. Refer to Air Conditioning O-Ring Seal Replacement . 5. Install the GE-45268-115   adapter in place of the TXV using an oversized seal washer. Caution: Refer to Fastener Caution . 6. Install the TXV mounting bolts and tighten to 15 N·m (11 lb in) . 7. Install new washers onto the liquid line and the suction hose. Refer to Air Conditioning O-Ring Seal Replacement . 8. Connect the liquid line and the suction hose to the GE-45268-115   adapter using an oversized seal washer. 9. Install the TXV block fitting nut and tighten to 19 N·m (14 lb in) . 10. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement .            11. Remove the A/C refrigerant filter (1). Refer to Air Conditioning (AC) Refrigerant Filter Replacement . Note:  The filter inside the GE-45268-1   adapter is serviceable. Remove and DISCARD check valve from the filter. 12. Service the filter before each flush. Note:  Assure that the suction and discharge ports on G-45268-10 correspond to the suction and discharge ports on the compressor hose assembly. 13. Install new sealing washers onto the A/C compressor and the condenser hose. Refer to Air Conditioning O-Ring Seal Replacement . Assure that the suction and discharge ports on the GE-45268-10   adapter correspond to the suction and the discharge ports on the A/C compressor to the condenser hose. 14. Install the GE-45268-10   filter adapter to the A/C compressor to the condenser hose. 15. Connect the GE-45268-1   filter to the G-45268-7   adapter . 16. Connect the blue hose from the A/C filling device to the GE-45268   adapter . 17. Connect the red hose from the A/C filling device to the GE-45268   adapter . 18. Disconnect the blue hose from the A/C filling device to the GE-45268-1   adapter . 19. Disconnect the GE-45268-1   adapter from the GE-45268-10   adapter . 20. Remove the GE-45268-10   adapter from the A/C compressor to the condenser hose. Note:  Flushing will remove all PAG oil from the A/C system. The A/C system must be replenished with the correct amount of PAG oil. 21. If you will reinstall the removed A/C compressor, perform the following procedure:   •  Remove the A/C compressor drain plug. Refer to Air Conditioning Compressor Oil Drain Plug Replacement .   •  Drain PAG oil from the A/C compressor. Rotate compressor input shaft to assist in draining the PAG oil from compressor.   •  Add the total system capacity of PAG oil to the A/C compressor. Refer to Refrigerant System Specifications .   •  Add one bottle of the GE-41447   tracer dye .   •  Install the A/C compressor drain plug. Refer to Air Conditioning Compressor Oil Drain Plug Replacement . Note:  Flushing will remove fluorescent leak detection dye from A/C system. 22. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement . 23. Install the new A/C refrigerant filter. Refer to Air Conditioning (AC) Refrigerant Filter Replacement . 24. Remove the TXV block fitting nut. 25. Disconnect the liquid line and the suction line from the GE-45268-115   adapter . 26. Remove the TXV bolts retaining GE-45268-115   adapter . 27. Remove the GE-45268-115   adapter . 28. Inspect the TXV for debris. Clean or replace as needed. 29. Install the TXV. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement . 30. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging . 31. Leak test fittings using the BO-42220   lamp .

12 Heating & A/C