Heating, Ventilation and Air Conditioning: Maintenance Pontiac G6 I

Forward Flushing Setup

1. Install both J 45268-9 onto J 45268-10.
2. Install J 45268-7 onto suction side of J 45268-10.
3. Install J 45268-8 onto discharge side of J 45268-10.

Reverse Flushing Setup

1. Install both J 45268-9 onto J 45268-10.
2. Install J 45268-8 onto suction side of J 45268-10.
3. Install J 45268-7 onto discharge side of J 45268-10.

Flush Procedure

1. Recover refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-243028-S28276360932006082100000) .
2. Remove thermal expansion valve (TXV). Refer to «Thermal Expansion Valve Replacement»(ref-243028-S04543421212006082100000) .
3. Install TXV stud onto J 45268-115.
4. Install new sealing washers onto evaporator core. Refer to «Sealing Washer Replacement»(ref-243028-S41426825992006082100000) .
5. Install J 45268-115 in place of TXV.
6. Install TXV mounting bolts. Tighten: Tighten bolts to 7 N.m (62 lb in).
7. Install new washers onto liquid line and suction hose. Refer to «Sealing Washer Replacement»(ref-243028-S41426825992006082100000) .
8. Connect liquid line and suction hose to J 45268-115.
9. Install TXV block fitting nut. Tighten: Tighten nut to 27 N.m (20 lb ft).
10. Remove A/C compressor. Refer to «Compressor Replacement (LE5)»(ref-243028-S04705105772006082100000) , «Compressor Replacement (LX9)»(ref-243028-S25823289052006082100000) or «Compressor Replacement (LZ9)»(ref-243028-S16491314972006082100000) .
11. Remove A/C refrigerant filter. Refer to «Air Conditioning (A/C) Refrigerant Filter Replacement»(ref-243028-S25640721782006082100000) .
12. Service filter with ACDelco P/N GF 470, before each flush.
13. Install J 45268-10 to compressor hose assembly.
14. Connect J 45268-1 flush filter to J 45268-7 flush adapter.
15. Connect blue hose from J 43600 to J 45268-1 flush filter adapter. See «Special Tools»(ref-243028-S11165728312006082100000) .
16. Connect red hose from J 43600 to J 45268-8 flush adapter. See «Special Tools»(ref-243028-S11165728312006082100000) .
17. Flush A/C system. Follow instructions supplied with J 43600 . See «Special Tools»(ref-243028-S11165728312006082100000) .
18. Disconnect red hose from J 43600 to J 45268-8 flush adapter. See «Special Tools»(ref-243028-S11165728312006082100000) .
19. Disconnect blue hose from J 43600 to J 45268-1 flush filter adapter. See «Special Tools»(ref-243028-S11165728312006082100000) .
20. Disconnect J 45268-1 flush filter from J 45268-10 flush adapter.
21. Remove J 45268-10 from compressor hose assembly.
22. If you will reinstall the removed A/C compressor, perform the following procedure: Remove A/C compressor drain plug. Drain PAG oil from 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 Capacities»(ref-243028-S41454679322006082100000) . IMPORTANT: Flushing will remove fluorescent leak detection dye from A/C system. Add one bottle of J 41447 . See «Special Tools»(ref-243028-S11165728312006082100000) . Install A/C compressor drain plug. Tighten: Tighten drain plug to 15 N.m (11 lb ft).
23. Install A/C compressor. Refer to «Compressor Replacement (LE5)»(ref-243028-S04705105772006082100000) , «Compressor Replacement (LX9)»(ref-243028-S25823289052006082100000) or «Compressor Replacement (LZ9)»(ref-243028-S16491314972006082100000) .
24. Install new A/C refrigerant filter. Refer to «Air Conditioning (A/C) Refrigerant Filter Replacement»(ref-243028-S25640721782006082100000) .
25. Remove TXV block fitting nut.
26. Disconnect liquid line and suction line from J 45268-115.
27. Remove TXV bolts retaining J 45268-115.
28. Remove J 45268-115.
29. Inspect TXV for debris. Clean or replace as needed.
30. Install TXV. Refer to «Thermal Expansion Valve Replacement»(ref-243028-S04543421212006082100000) .
31. Evacuate and recharge A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-243028-S28276360932006082100000) .
32. Leak test fittings using J 42220 . See «Special Tools»(ref-243028-S11165728312006082100000) .

Draining Procedure

1. Remove the compressor crankcase oil drain plug and drain the crankcase into a clean, graduated container.
2. Drain the oil from both the suction and discharge ports of the removed compressor into the same container. Rotate the compressor shaft to assist in draining the compressor.
3. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
4. Properly discard the used refrigerant oil.