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DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET2003MALIBU V6-3.1L VIN JREPAIR AND DIAGNOSISHEATING AND AIR CONDITIONINGSERVICE AND REPAIRFLUSHING
2003 Chevrolet Malibu V6-3.1L VIN J
Flushing
2003 Chevrolet Malibu V6-3.1L VIN JSECTION Flushing
FLUSHING
TOOLS REQUIRED
- J 43600 Air Conditioning Service Center
- J 45268 Flush Adapter Kit
- J 41447 Leak Detection Dye
- J 41459 Leak Detection Dye Injector
- J 42220 Universal 12V Leak Detection Lamp
IMPORTANT: 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 PAG oil
- Desiccant, following a desiccant bag failure
- Overcharge of PAG oil
- Refrigerant contamination
1. Recover the refrigerant.
IMPORTANT: Warmer engine or ambient temperature decreases the refrigerant recovery time during the A/C flush procedure.
2. Remove the orifice tube.
3. Connect the A/C lines with the orifice tube removed.
4. Remove the A/C compressor.
5. Install J 45268 - 3 to the A/C compressor hose assembly.
6. Forward flow refrigerant flushing is recommended for contaminated refrigerant or PAG oil. Perform the following procedure:
6.1. Service the filter with ACDelco P/N GF 470, before each flush. Connect J 45268 - 1 flush filter to the suction port of J 45268 - 3 flush adapter.
IMPORTANT: The filter inside J 45268 - 1 is serviceable. Remove and discard the check valve from the filter.
6.2. Connect the blue hose from J 43600 to J 45268 - 1 flush filter adapter.
6.3. Connect the red hose from J 43600 to J 45268 - 3.
7. Reverse flow refrigerant flushing is recommended for desiccant bag failure only. Perform the following procedure and replace the accumulator when the flush is complete:
7.1. Service the filter with ACDelco P/N GF 470, before each flush. Connect J 45268 - 1 flush filter to the discharge port of J 45268 - 3 flush adapter.
IMPORTANT: The filter inside J 45268 - 1 is serviceable. Remove and discard the check valve from the filter.
7.2. Connect the blue hose from J 43600 to J 45268 - 1 flush filter adapter.
7.3. Connect the red hose from J 43600 to the suction port of J 45268 - 3.
8. Flush the A/C system. Follow the instructions supplied with J 43600.
IMPORTANT: Close the valve on the external refrigerant tank before starting the flush process.
9. Remove J 45268 - 3 from the A/C compressor hose assembly.
10. If the removed A/C compressor will be reinstalled, perform the following steps:
10.1. Remove the A/C compressor drain plug.
10.2. Rotate the compressor input shaft to assist in draining the PAG oil from the compressor.
10.3. Drain the PAG oil from the A/C compressor.
10.4. Install the A/C compressor drain plug.
Tighten
Tighten the drain plug to 20 N.m (15 lb ft).
10.5. Add the total system capacity of PAG oil to the A/C compressor.
IMPORTANT: Flushing will remove all the PAG oil from the A/C system. Replenish the A/C system with the correct amount of PAG oil.
11. If you are replacing the A/C compressor after flushing the system, perform the following steps:
11.1. Do NOT drain the new PAG oil from the compressor. Deduct the amount of PAG oil shipped with the service compressor from the amount of PAG oil listed in the capacities table.
11.2. Add the calculated amount of oil to the compressor, as needed.
12. Install the A/C compressor.
13. Inspect the orifice tube for debris. Clean or replace as needed.
14. Install the orifice tube.
15. Evacuate and recharge the A/C system.
16. Add one bottle of J 41447 using J 41459.
IMPORTANT: Flushing will remove the fluorescent leak detection dye from the A/C system.
17. Leak test the fittings using J 42220.
TOOLS REQUIRED
- J 43600 Air Conditioning Service Center
- J 45268 Flush Adapter Kit
- J 41447 Leak Detection Dye
- J 41459 Leak Detection Dye Injector
- J 42220 Universal 12V Leak Detection Lamp
IMPORTANT: 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 PAG oil
- Desiccant, following a desiccant bag failure
- Overcharge of PAG oil
- Refrigerant contamination
1. Recover the refrigerant.
IMPORTANT: Warmer engine or ambient temperature decreases the refrigerant recovery time during the A/C flush procedure.
2. Remove the orifice tube.
3. Connect the A/C lines with the orifice tube removed.
4. Remove the A/C compressor.
5. Install J 45268 - 3 to the A/C compressor hose assembly.
6. Forward flow refrigerant flushing is recommended for contaminated refrigerant or PAG oil. Perform the following procedure:
6.1. Service the filter with ACDelco P/N GF 470, before each flush. Connect J 45268 - 1 flush filter to the suction port of J 45268 - 3 flush adapter.
IMPORTANT: The filter inside J 45268 - 1 is serviceable. Remove and discard the check valve from the filter.
6.2. Connect the blue hose from J 43600 to J 45268 - 1 flush filter adapter.
6.3. Connect the red hose from J 43600 to J 45268 - 3.
7. Reverse flow refrigerant flushing is recommended for desiccant bag failure only. Perform the following procedure and replace the accumulator when the flush is complete:
7.1. Service the filter with ACDelco P/N GF 470, before each flush. Connect J 45268 - 1 flush filter to the discharge port of J 45268 - 3 flush adapter.
IMPORTANT: The filter inside J 45268 - 1 is serviceable. Remove and discard the check valve from the filter.
7.2. Connect the blue hose from J 43600 to J 45268 - 1 flush filter adapter.
7.3. Connect the red hose from J 43600 to the suction port of J 45268 - 3.
8. Flush the A/C system. Follow the instructions supplied with J 43600.
IMPORTANT: Close the valve on the external refrigerant tank before starting the flush process.
9. Remove J 45268 - 3 from the A/C compressor hose assembly.
10. If the removed A/C compressor will be reinstalled, perform the following steps:
10.1. Remove the A/C compressor drain plug.
10.2. Rotate the compressor input shaft to assist in draining the PAG oil from the compressor.
10.3. Drain the PAG oil from the A/C compressor.
10.4. Install the A/C compressor drain plug.
Tighten
Tighten the drain plug to 20 N.m (15 lb ft).
10.5. Add the total system capacity of PAG oil to the A/C compressor.
IMPORTANT: Flushing will remove all the PAG oil from the A/C system. Replenish the A/C system with the correct amount of PAG oil.
11. If you are replacing the A/C compressor after flushing the system, perform the following steps:
11.1. Do NOT drain the new PAG oil from the compressor. Deduct the amount of PAG oil shipped with the service compressor from the amount of PAG oil listed in the capacities table.
11.2. Add the calculated amount of oil to the compressor, as needed.
12. Install the A/C compressor.
13. Inspect the orifice tube for debris. Clean or replace as needed.
14. Install the orifice tube.
15. Evacuate and recharge the A/C system.
16. Add one bottle of J 41447 using J 41459.
IMPORTANT: Flushing will remove the fluorescent leak detection dye from the A/C system.
17. Leak test the fittings using J 42220.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.