Flushing procedure (manuel)

The flushing of the entire system can be done by a simple flush gun and some high evaporative flush. This way is fully acceptable and in many
situations better than flushing in a closed loop where the dirt will simply just be flushed around in the entire AC system.

Flush gun
be 100% clean inside)

High evaporative flush

Safety goggles

an appropriate plastic or metal container (it must

Before the flushing procedure can begin it is necessary to remove following components from the system:
1.
2.
3.
4.
5.

Compressor
Receiver / drier
Orifice Tube
Expansion Valve
Parallel Condenser (In case the condenser has all tubes connected in a serial connection it can stay on the vehicle this is typically on vehicles
produced before 1995))

Connect the Flush Gun to dry compressed air - or preferable Nitrogen.

The flushing procedure looks as following:
1. Flush the pipe between the D side of the compressor and the inlet of the condenser (flush both in the flow direction and opposite the flow
direction). Use the above mentioned container to collect the flushing fluid and dirt that comes out. Keep flushing (back and forward) until the fluid
that enters the container is clean and free of particles.
2. Flush the condenser this point should only be carried out in case the condenser has all tubes connected as one serial connection (typical in cars
older than mid nineties)
3. Flush the pipe between the outlet of the condenser and the inlet of the receiver drier. Flush both in the flow direction and opposite the flow
direction). Use the above mentioned container to collect the flushing fluid and dirt that comes out. Keep flushing (back and forward) until the fluid
that enters the container is clean and free of particles. Please note that in many cases the filter drier is integrated in the condenser in that case go
directly to point three.

4. Flush the pipe between the outlet of the receiver drier and the inlet of the expansion valve. Flush both in the flow direction and opposite the flow
direction). Use the above mentioned container to collect the flushing fluid and dirt that comes out. Keep flushing (back and forward) until the fluid
that enters the container is clean and free of particles.

5.

Flush the pipe between the outlet of the expansion valve and the inlet of the evaporator. Flush both in the flow direction and opposite the flow
direction). Use the above mentioned container to collect the flushing fluid and dirt that comes out. Keep flushing (back and forward) until the fluid
that enters the container is clean and free of particles.

6. Flush the pipe between the outlet of the expansion valve and the inlet (S) on the compressor. Flush both in the flow direction and opposite the flow
direction). Use the above mentioned container to collect the flushing fluid and dirt that comes out. Keep flushing (back and forward) until the fluid
that enters the container is clean and free of particles.
In case that any of the 6 flushing points show any sign on internal blockage, please exchange the component (Hoses or the evaporator or condenser)
Hereafter the system can be reassembled with new compressor, new receiver drier,(new orifice tube), new expansion valve and finally new
parallel condenser. The must be installed new O-rings between all dismantled parts. Important! Please DRAIN the oil out of the compressor
BEFORE installing it on the vehicle and turn the compressor shaft minimum 10 revolutions by hand to ensure that there are no oil located over
the pistons or other moving inside parts in the compressor. (Please bear in mind that the compressor is a gas pump, not an oil pump)
Now the entire system is ready for evacuation of the moisture and air (and remaining flush) that has entered the system the evacuation (vacuum)
period must be minimum 30 minutes.
Recharge the system with the appropriate refrigerant and oil amount (mostly R134a and PAG oil) It is also recommended to add a small amount of
dye (approx 10ml) to the system because that will enable the service technician to trace leaks by the use of UV light in case of future leaks.
Oil notice:
Some AC compressors are supplied with the full amount of oil for the entire system, in that case it is recommended to drain the oil out of the
compressor and charge it into the AC system together with the refrigerant (this is done in a filling station) this procedure will secure that the
whole system is lubricated before engine startup. Please remember to turn the compressor shaft minimum 10 revolutions by hand BEFORE
charging the system to ensure that there is no oil located over the pistons or other moving inside parts.

In case the system is being manually charged it is recommended to add of the oil into the suction port on the compressor and one into the
condenser and into the filter/drier and finally the last into the evaporator and hereafter charge the system with refrigerant. This procedure
will also secure a full lubrication of the entire system before engine startup. Please remember to turn the compressor shaft minimum 10
revolutions by hand BEFORE charging the system to ensure that there is no oil located over the pistons or other moving inside parts.

Other Flushing methods:

The above mentioned flushing and charging procedure is a standard procedure and its of course possible to purchase much more
sophisticated flushing stations and refrigerant cleaning stations but the intention with this bulletin is to give the installer the basic
knowledge and underline the importance of 100% cleanness in the AC system after an AC service. The intention with this bulletin is also
to underline that a compressor will be seriously damaged if it pumps oil instead of gas.