QUICK REFERENCE GUIDE

A/C SYSTEM FLUSHING

MAINTENANCE INFORMATION
MAINTENANCE INFORMATION
A/C FLUSHING PROCEDURES
CAUTION: A /C service should be completed with a service station that meets J2788 standards and has had all the current required maintenance procedures completed.
1. Empty oil recovery bottle and then use the A/C service station to identify and
recover refrigerant.
2. Check recovery bottle for excessive oil.
3. Remove the drier, or orifice tube, from vehicle. Use drier cutter tool to cut drier
open 101.6mm (4 inches) from the top.
4. Carefully remove the desiccant carrier from drier to prevent oil splash and then
remove press in retainer to access the filter element. Inspect filter element or
orifice tube screen for metal shavings that indicate a failed compressor.
5. Determine the repairs required based on the level in the oil recovery bottle and
inspection of the drier or orifice tube.
WARNING: The A/C service station filters must be replaced after recovering
refrigerant from a system that was determined to have metal contamination. Failure
to replace the filters will result in premature compressor failure due to metal
contaminants re-entering the system during the refrigerant charging process.
6. Remove components that require replacement.
7. Inspect all required flush adapters for damage and replace any damaged adapter
seals. Install required adapters on the vehicle.
8. Place small lines removed during the adapter installation process in a suitable
container filled with solvent to assist in cleaning.
9. Check the discharge assembly for flush solvent left from the last job. Excessive
VOCs could be released into the atmosphere if there is excess solvent in the barrel.
10. Remove pulse valve assembly from the flush tank. Fill flush tank with 1 gal of
solvent for Day-Cabs and 2 gal of solvent for Sleeper-Cabs and then re-install
pulse valve assembly.
11. Connect discharge hose to the flush fitting on the vehicle using the
cam-lock coupling.
12. Connect trigger assembly to the flush fitting on the vehicle using the quick
coupling on the short trigger hose.
13. Connect trigger assembly to flush tank assembly using the quick coupling on the
long hose.
14. Connect discharge hose to discharge tank using the cam-lock coupling.
QUICK REFERENCE GUIDE: 2004-2010 VEHICLES
15. Connect nitrogen regulator to pressure regulator on flush tank assembly.
16. Open valve on top of the nitrogen tank all the way.
17. Use regulator knob to adjust outlet pressure to 120psi, providing a 100psi
working pressure.
18. Squeeze trigger to introduce solvent into the system and watch the discharge hose
sight glass. Solvent should run clear and be free of debris. Release trigger after the
appropriate amount of solvent has been injected.
19. Flushing solvent must be purged from each component using nitrogen after the
solvent injection is complete.
20. Start by disconnecting the trigger-to-tank quick coupler and then connect the
trigger assembly to the quick coupling located on the nitrogen regulator assembly.
21. Squeeze the trigger to introduce nitrogen directly into the component being
purged. While purging, adjust regulator to 200psi and then down to 100psi
working pressure. Purging is complete when 100 psi is reached.
22. Once purging is complete, remove the flush adapters and cap off each end of the
component. Repeat steps 11 through 22 until all other lines and components are
flushed and purged.
23. Drain discharge barrel of flushing solvent. Leave the top of the barrel off.
24. Set nitrogen pressure at 120 psi to provide 100 psi working pressure.
25. Use supplied flexible brush to scrub the inside of the tube(s) that are
soaking in solvent.
WARNING: To avoid contact with flush solvent always direct the discharge end of
component and open thermistor bosses into the discharge barrel while performing
cleaning and purging operations.
26. Use the blow gun supplied to blow any loose particles out of the tubes and dry the
solvent. Cap off each end of the component as soon as the purging is complete,
and then move to the next component. Continue flush procedures until all the
small components are flushed and purged.
27. If the system was oil overcharged, replace accumulator or filter-drier.
28. If the vehicle had a compressor failure, replace compressor, condenser, orifice tube
or TXVs, thermistors, and the accumulator or filter-drier.
© 2012 Navistar, Inc. • Lisle, IL 60532 • All rights reserved. • 08/2012
MAINTENANCE INFORMATION
QUICK REFERENCE GUIDE: 2004-2010 VEHICLES
A/C SYSTEM FLUSHING
Flushing is a required service procedure for A/C systems that have a failed compressor or an oil overcharge.

PURPOSE OF FLUSHING
• Ensures complete removal of contamination from A/C system components
• Guarantees Navistar® warranty support for vehicles with a warrantable failure
• Increases vehicle up-time and customer satisfaction

APPLICATIONS:
The A/C Flush Tool set applies to all International® trucks manufactured between model years 2004-2012.

VEHICLE APPLICATIONS
TERRASTAR, DURASTAR, WORKSTAR,
PAYSTAR & 9900 ORIFICE TUBE
TRANSTAR, PROSTAR, LONESTAR
2007 2008 2010 2010 PRE-2007
FRONT EVAPORATOR LIQUID 19-353-07 19-353-07
19-094-01 19-094-01 19-094-02
FRONT EVAPORATOR SUCTION 19-353-01 19-353-01
SUCTION LINE AT COMPRESSOR 19-353-03 19-353-03 19-353-03 19-353-03 19-353-03
SUCTION LINE PLUG 19-353-02 19-353-02 19-353-02
SUCTION LINE AT TXV 19-353-04 19-353-04 19-353-04 19-353-04
CONDENSER LINE AT COMPRESSOR 19-353-06 19-353-06 19-353-06 19-353-06 19-353-06
CONDENSER LINE PLUG 19-353-08 19-353-08
CONDENSER LINE LOOP 19-043-01 19-043-01 19-043-01 19-043-01 19-043-01
CONDENSER LINE AT RECEIVER/DRYER 19-353-05 19-353-05 19-353-05 19-353-10 19-353-05
EVAPORATOR LINE AT RECEIVER/DRYER 19-353-11
SLEEPER REAR SUCTION LINE 19-353-03 19-353-03 19-353-03
SLEEPER REAR LIQUID LINE 19-353-06 19-353-06 19-353-06
SLEEPER REAR LINES AT REAR TXV 19-632-01 19-632-01 19-632-01 19-632-02
SLEEPER EVAPORATOR 19-094-01 19-094-01 19-094-01
SLEEPER EVAPORATOR NO-IDLE 19-094-02
CONDENSER INLET 19-353-07 19-353-07 19-353-07 19-353-07 19-353-07
CONDENSER OUTLET 19-353-09 19-353-09 19-353-09 19-353-09 19-353-09

© 2012 Navistar, Inc. All rights reserved.

 MAINTENANCE INFORMATION
QUICK REFERENCE GUIDE: 2004-2010 VEHICLES
A/C FLUSH TOOL IDENTIFICATION

19-352-03
TC3Q 19-352-01 19-352-02 NITROGEN REGULATOR
DRIER CUTTER TOOL FLUSH TANK ASSEMBLY DISCHARGE ASSEMBLY ASSEMBLY

19-043-01 19-094-01 19-094-02

19-353-01 19-353-02 19-353-03 19-353-04

19-353-05 19-353-06 19-353-07 19-353-08

19-353-09 19-353-10 19-353-11 19-632-01 19-632-02

© 2012 Navistar, Inc. All rights reserved.

QUICK REFERENCE GUIDE: 2004-2010 VEHICLES
FLUSH ADAPTER LOCATIONS
CONDENSER

PRE-2007 ORIFICE TUBE INLET OUTLET

19-353-07 19-353-09

19-353-06
OUTLET 19-043-01 19-353-05

COMPRESSOR
INLET

INLET ORIFICE TUBE

OUTLET INLET
19-353-03 OUTLET
OUTLET INLET
ACCUMULATOR
EVAPORATOR
19-353-04 19-353-01 19-353-07

2010 PAYSTAR & 9900 CONDENSER

INLET OUTLET

19-353-07 19-353-09

19-353-06 19-043-01
OUTLET

COMPRESSOR EVAPORATOR

19-094-02
INLET
19-353-03
19-632-02 TXV
19-353-11
OUTLET INLET

19-353-10
OUTLET INLET
RECEIVER/DRIER

© 2012 Navistar, Inc. All rights reserved.

TERRASTAR | DURASTAR | WORKSTAR CONDENSER

TRANSTAR | PROSTAR | LONESTAR INLET OUTLET

2007
19-353-07 19-353-09

19-353-06
OUTLET

COMPRESSOR
19-043-01
INLET

19-353-03

19-353-04
19-353-01
OUTLET OUTLET
19-353-05
EVAPORATOR TXV
RECEIVER/DRIER
INLET INLET
19-353-07 OUTLET INLET

2010 CONDENSER

INLET OUTLET

19-353-07 19-353-09

19-353-06
OUTLET

COMPRESSOR 19-043-01

INLET
19-353-03

19-353-04
OUTLET OUTLET
19-353-05
EVAPORATOR TXV
RECEIVER/DRIER

INLET INLET OUTLET INLET

19-094-01

© 2012 Navistar, Inc. All rights reserved.

 2007 PROSTAR/LONESTAR
19-353-09
W/SLEEPER
OUTLET

CONDENSER 19-043-01 19-353-05

19-353-08

INLET
19-353-07
OUTLET
19-353-06 19-353-06

COMPRESSOR
INLET
RECEIVER/
DRIER
INLET OUTLET
19-632-01 19-353-03 19-353-02

19-353-03

19-353-04
CAB TXV
OUTLET INLET

INLET SLEEPER TXV OUTLET 19-353-07

19-094-01

19-353-01

INLET OUTLET OUTLET INLET

SLEEPER EVAPORATOR CAB EVAPORATOR

© 2012 Navistar, Inc. All rights reserved.

FLUSH ADAPTER LOCATIONS QUICK REFERENCE GUIDE: 2004-2010 VEHICLES

2010 PROSTAR/LONESTAR
OUTLET
19-353-09 W/ SLEEPER

CONDENSER 19-043-01

INLET
19-353-07

OUTLET
19-353-06

COMPRESSOR

19-353-02
INLET
19-353-03
19-353-03
19-632-01
RECEIVER/DRIER ASSEMBLY

INLET

19-353-04
INLET OUTLET OUTLET
SLEEPER TXV 19-353-05
19-094-01

19-094-02*

OUTLET CAB TXV INLET 19-353-06

INLET OUTLET

19-094-01
SLEEPER EVAPORATOR
OUTLET INLET

CAB EVAPORATOR

WITH 12-VOLT NO-IDLE A/C*

© 2012 Navistar, Inc. All rights reserved.