Chevrolet Sonic Repair Manual: 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.

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-ring onto GE 45268-10 adapter .
2. Install GE 45268-8 fitting O-ring onto suction side of GE 45268-10 adapter .
3. Install GE 45268-7 fitting O-ring onto discharge side of GE 45268-10 adapter .

Reverse Flushing Setup

Note:

• Reverse flow refrigerant flush is recommended for desiccant bag failure. Replace condenser/receiver dehydrator assembly when A/C flush is complete and perform the following procedure:
• 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-ring onto GE 45268-10 adapter .
2. Install GE 45268-8 fitting O-ring onto suction side of GE 45268-10 adapter .
3. Install GE 45268-7 fitting O-ring onto discharge side of 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 GE 45268-115 adapter .
4. Install new sealing washers onto evaporator core. Refer to Air Conditioning O-Ring Seal Replacement.
5. Install GE 45268-115 adapter in place of the TXV.

Caution:

Refer to Fastener Caution.

6. Install the TXV mounting bolts and tighten to 7 Y (62 lb in)

   .

7. Install new washers onto liquid line and suction hose. Refer to Air Conditioning O-Ring Seal Replacement.
8. Connect liquid line and suction hose to GE 45268-115 adapter .
9. Install the TXV block fitting nut and tighten to 22 Y (16 lb ft)

   .

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 GE 45628-1 adapter is serviceable. Remove and discard check valve from the filter.

12. Service the filter before each flush.

Note:

Assure that suction and discharge ports on J 45268-10 correspond to suction and discharge ports on compressor hose assembly.

13. Install new sealing washers onto A/C compressor and condenser hose. Refer to Air Conditioning O-Ring Seal Replacement. Assure that suction and discharge ports on GE 45268-10 adapter correspond to suction and discharge ports on A/C compressor to condenser hose.
14. Install GE 45268-10 filter adapter to the A/C compressor to condenser hose.
15. Connect GE 45268-1 filter to J 45268-7 adapter .
16. Connect blue hose from A/C filling device to GE 45268 adapter .
17. Connect red hose from A/C filling device to GE 45268 adapter .
18. Disconnect blue hose from A/C filling device to GE 45268-1 adapter .
19. Disconnect GE 45268-1 adapter from GE 45268-10 adapter .
20. Remove GE 45268-10 adapter from the A/C compressor to 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:

• 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 A/C compressor. Refer to Refrigerant System Specifications.
• Add one bottle of GE 41447 tracer dye .

Note:

Flushing will remove fluorescent leak detection dye from A/C system.

Install the A/C compressor. Refer to Air Conditioning Compressor Replacement.

Install new A/C refrigerant filter. Refer to Air Conditioning (AC) Refrigerant Filter Replacement.

Remove the TXV block fitting nut.

Disconnect liquid line and suction line from GE 45268-115 adapter .

Remove the TXV bolts retaining GE 45268-115 adapter .

Remove GE 45268-115 adapter .

Inspect the TXV for debris. Clean or replace as needed.

Install the TXV. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement.

Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.

Leak test fittings using BO 42220 lamp .

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