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Flushing

Special Tools

    • GE-42220 Universal 12V Leak Detection Lamp
    • GE-48800 CoolTech A/C Recharge Machine
    • GE-45268 Flush Adaptor Kit

For equivalent regional tools. Refer to Special Tools .

ACR2000 (GE-48800) Hose Flush Procedure

Note: 

   • The following hose flushing procedure must be performed every time the ACR2000 (GE-48800) is used on the hybrid vehicles. It must be completed before the ACR2000 (GE-48800) is connected to the vehicle to begin a diagnostic or service procedure.
   • The high voltage (HV) electric air conditioning (A/C) compressor uses a polyolester (POE) refrigerant oil instead of a polyalkylene glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation.
   • The following hose flush procedure is required to prevent oil cross-contamination. Laboratory testing has shown that flushing the ACR2000 (GE-48800) using the following procedure will minimise oil cross-contamination to a negligible amount (<500ppm).
   • Failure to flush the ACR2000 (GE-48800) hoses before adding refrigerant to a hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may also cause a battery energy control module hybrid battery voltage system isolation lost diagnostic trouble code (DTC P1AE7) to be set. Additionally the A/C system warranty will be voided.
   • The ACR2000 (GE-48800) will need to be retrofitted with a GE-48800-50 (Hose-ACR2000 Oil Flush Loop) to be able to perform the following procedure. All hybrid dealers will receive a GE-48800-50, with installation instructions, which is a component of the hybrid essential tool package. Dealers not included in the hybrid marketing plan and needing to service a hybrid vehicle can obtain the GE-48800-50 from SPX Kent Moore, 1-800-GM-TOOLS (1-800-468-6657).
      - The GE-48800-50 Retrofit Kit replaces the existing hose mount fittings on the ACR2000. Installation instructions are included to properly update the ACR2000 for hybrid vehicle A/C service.
      - New hybrid compliant A/C refrigerant recharging equipment (GE-48800) will replace current ACR2000 equipment. GE-48800 meets new SAE refrigerant recovery standard J-2788 and is specially designed for GM hybrid vehicle A/C service.

Before Beginning the Hose Flushing Procedure

  1. Always allow the ACR2000 to complete the hose flush cycle to assure that all oil and refrigerant is removed from the hoses and the ACR2000 flow control circuit.
  2. Assure the ACR2000 has at least 4.08 kg (9 lb) of chargeable refrigerant before proceeding.
  3. A Low Filter Flow message displayed during the hose flushing process indicates that the hose couplers are not connected or open.

Hose Flushing Procedure

  1. Connect the ACR2000 service hose couplers to the GE-48800-50 hose flush adapter fittings and open the service hose coupler valves.
  2. Power on the ACR2000.
  3. If there is positive pressure in the ACR2000 service hoses, press START to recover the service hoses. If there is 88-98 kPa (26-29 Hg) of vacuum showing on the display screen, skip to step 7.
  4. Press Vacuum.
  5. Press Start. Allow the vacuum programme to run until the display screen shows between 88-98 kPa (26-29 Hg).
  6. Press Pause.
  7. Press Main Menu.
  8. Press Scroll Menu.
  9. Press Oil Flush.
  10. Press Next.
  11. Enter 03:00 (for a three minute flush) and press Start.
  12. The ACR2000 will now flush the service hoses for three minutes and then recover the refrigerant
  13. Close the ACR2000 service hose couplers and remove the GE-48800-50 hose flush adapter.
  14. The ACR2000 can now be connected to the hybrid vehicle to perform the A/C system diagnostic or service procedures.

Note: Flushing with the ACR 2000 is not intended to remove metal from the A/C system.

Flushing is intended to remove the following contaminants:

    • Contaminated polyolester (POE) oil
    • Desiccant, following a desiccant bag failure
    • Overcharge of POE oil
    • Refrigerant contamination

    Note: Warmer engine or ambient temperature decreases the refrigerant recovery time during the A/C flush procedure.

  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging : High Voltage Electric Compressor .
  2. Remove the air conditioning refrigerant desiccant. Refer to Air Conditioning Refrigerant Desiccant Replacement .
  3. Remove the air conditioning refrigerant desiccant plug from the desiccant cartridge.
  4. Install the air conditioning refrigerant desiccant plug without the desiccant cartridge.
  5. Remove the evaporator thermal expansion valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement : Drive Motor Battery Coolant Cooler → A/C Evaporator
  6. Install GE-45268-115 to the evaporator.
  7. Remove the drive motor battery cooler thermal expansion valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement : Drive Motor Battery Coolant Cooler → A/C Evaporator
  8. Install another GE-45268-115 to the drive motor battery cooler.
  9. Install A/C evaporator tube to both GE-45268-115.
  10. Install A/C evaporator TXV tube to both GE-45268-115 using an oversized seal washer.
  11. Remove the A/C and drive motor battery cooling compressor. Refer to Air Conditioning and Drive Motor Battery Cooling Compressor Replacement
  12. Inspect the end of the suction hose for a suction screen.
  13. Remove the suction screen, if installed.
  14. Install GE-45268-4 to the A/C compressor suction hose.
  15. Install GE-452688-5 to the A/C compressor discharge hose.

    16. 787687
  16. Forward flow refrigerant flushing is recommended for contaminated refrigerant or POE oil.
  17. Perform the following procedure:

    18.         Note: The filter inside the GE-45268-1 is serviceable. Remove and discard the check valve from the filter.

    17.1. Service the filter with ACDelco P/N GF 470 before each flush.

    Connect the GE-45268-1 flush filter to the suction port of the GE-45268-4 flush adapter.

    17.2. Connect the blue hose from the GE-48800 ACR 2000 Air Conditioning Service Centre to the J 45268-1 flush filter adapter.
    17.3. Connect the red hose from the GE-48800 ACR 2000 Air Conditioning Service Centre to the GE-45268-5 flush adapter.
  18. Reverse flow refrigerant flushing is recommended for desiccant cartridge failure.

    19.         Note: The filter inside the J 45268-1 is serviceable. Remove and discard the check valve from the filter.

    18.1. Service the filter with AC P/N GF 470, before each flush. Connect the J 45268-1 flush filter to the discharge port of the GE-45268-5 flush adapter.
    18.2. Connect the blue hose from the GE-48800 ACR 2000 Air Conditioning Service Centre to the J 45268-1 flush filter adapter.
    18.3. Connect the red hose from the GE-48800 ACR 2000 Air Conditioning Service Centre to the suction port of the GE-45268-4 flush adapter.

    Note: Close the valve on the external refrigerant tank, before starting the flush process.

  19. Flush the front A/C system. Follow the instructions supplied with the GE-48800 ACR 2000 Air Conditioning Service Centre .

    20. Note: Close the valve on the external refrigerant tank, before starting the flush process.

  20. Flush the A/C system. Follow the instructions supplied with the GE-48800 ACR 2000 Air Conditioning Service Centre
  21. Remove the GE-45268-4 from the A/C compressor suction hose.
  22. Remove the GE-45268-5 from the A/C compressor discharge hose.

    23. Note: Flushing will remove all the POE oil from the A/C system.

    The A/C system must be replenished with the correct amount of POE oil.

  23. If the removed A/C compressor is being reinstalled, perform the following procedure:
    24. • Drain the POE oil from the A/C compressor.
    • Add the total system capacity of POE oil to the A/C compressor. Refer to Refrigerant System Specifications .
  24. If you will replace the A/C compressor after flushing the system, perform the following procedure:
    25. 24.1. Refer to the Refrigerant System Specifications .
    24.2. DO NOT drain the new POE oil from the compressor.
    24.3. Deduct the amount of POE oil shipped with the service compressor from the amount of POE oil listed in the capacities table. Refer to Refrigerant System Specifications .
    24.4.  Add the calculated amount to the compressor, as needed.
  25. Install the air conditioning and drive motor battery cooling compressor. Refer to Air Conditioning and Drive Motor Battery Cooling Compressor Replacement

    26. Note: Flushing will remove the fluorescent leak detection dye from the A/C system.

  26. Replace the air conditioning refrigerant desiccant. Refer to Air Conditioning Refrigerant Desiccant Replacement .

    27. Note: The air conditioning refrigerant desiccant is manufactured with POE fluorescent leak detection dye wafer inside.

  27. Remove A/C evaporator TXV tube from both GE-45268-115.
  28. Remove A/C evaporator tube from both GE-45268-115.
  29. Remove both GE-45268-115.
  30. Install the drive motor battery cooler thermal expansion valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement : Drive Motor Battery Coolant Cooler → A/C Evaporator
  31. Install the evaporator thermal expansion valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement : Drive Motor Battery Coolant Cooler → A/C Evaporator
  32. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging : High Voltage Electric Compressor
  33. Leak test the fittings using GE-42220 Universal 12V Leak Detection Lamp
   


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