Heating, Ventilation, and Air Conditioning: Other Chevrolet Silverado 2500 HD

Fluorescent Leak Detector

Fluorescent dye will assist in locating any leaks in the A/C system.

1. Condensation on the evaporator core or the refrigerant lines may wash the PAG oil and fluorescent dye away from the actual leak. Condensation may also carry dye through the HVAC module drain.
2. Leaks in the A/C system will be indicated in a light green or yellow color when using the leak detection lamp. Use the leak detection lamp in the following areas: All fittings or connections that use seal washers or O-rings All of the A/C components The A/C compressor shaft seal The A/C hoses and pressure switches The HVAC module drain tube, if the evaporator core is suspected of leaking The service port sealing caps The sealing cap is the primary seal for the service ports.
3. Follow the instructions supplied with the J 42220 . See «Special Tools»(ref-277995-S42237343062008012100000) .
4. To prevent false diagnosis in the future, thoroughly clean the residual dye from any area where leaks were found. Use a rag and the approved J 43872 . See «Special Tools»(ref-277995-S42237343062008012100000) .

Fluorescent Dye Injection

1. Not all of the fluorescent dyes are compatible with PAG oil. Some types of dye decrease the oil viscosity or may chemically react with the oil.
2. R-134A leak detection dye requires time to work. Depending upon the leak rate, a leak may not become visible for between 15 minutes and 7 days.
3. To prevent false diagnosis, thoroughly clean any residual dye from the service port with a rag and the approved fluorescent dye cleaner J 43872 . See «Special Tools»(ref-277995-S42237343062008012100000) .

Halogen Leak Detector

Ensure that the vehicle has at least 0.45 kg (1 lb) of refrigerant in the A/C refrigeration system in order to perform a leak test. Refer to Refrigerant Recovery and Recharging for recharging the A/C system.

Clean and dry all surfaces in order to prevent a false warning. Liquids will damage the detector.

Follow the instructions supplied with the J 39400-A . See Special Tools .

A/C System Pressure Zone Classification - Gas Engine With Electric Cooling Fan or RPO HP2

A/C Performance Table - Gas Engine With Electric Cooling Fan or RPO HP2

Defrosting Insufficient

Defrosting Insufficient

Eliminating Air Conditioning Odor

Odors may be emitted from the air conditioning system primarily at start up in hot, humid climates. The following conditions may cause the odor

1. Debris is present in the HVAC module.
2. Microbial growth on the evaporator core

When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. To remove odors of this type, the microbial growth must be eliminated. Perform the following procedure

Deodorize the evaporator core using Deodorizing Aerosol Kit.

Perform the following steps in order to deodorize the A/C system

1. Ensure that the plenum which draws outside air into the HVAC module is clear of debris.
2. Disable the A/C compressor clutch operation by disconnecting the clutch coil electrical connector.
3. Dry the evaporator core by performing the following steps: Start the engine. Select the warmest temperature setting. Select the recirculation mode. Run the blower motor on high for 10 minutes.
4. Locate an area in the air conditioning duct between the blower motor and the evaporator core downstream of the blower motor.
5. Drill a 3.175 mm (0.125 in) hole where the hole will not interfere with or damage the following components: The blower motor The evaporator core Any other operating part the of system
6. Wear safety goggles and latex gloves in order to perform the following actions: Select the maximum blower speed. Insert the deodorizer extension tube into the hole to the mark on the extension tube. Use short spray bursts and vary the direction of spray for a 2-3 minute period of time.
7. Shut the engine OFF. Allow the vehicle to sit for 3-5 minutes.
8. Seal the 3.175 mm (0.125 in) hole with body sealer or RTV gasket compound.
9. Start the engine.
10. Operate the blower motor on high for 15-20 minutes to dry.
11. Reconnect the A/C compressor clutch coil electrical connector.
12. Verify proper clutch operation.

Refrigerant Recovery and Recharging

Tools Required

1. J 43600 ACR 2000 Air Conditioning Service Center. See «Special Tools»(ref-277995-S42237343062008012100000) .
2. J 45037 A/C Oil Injector. See «Special Tools»(ref-277995-S42237343062008012100000) .

Note. R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure.

Note. To avoid system damage use only R-134a dedicated tools when servicing the A/C system.

Note. Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result.

Note. R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing.

The J 43600 is a complete air conditioning service center for R-134a. See Special Tools . The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant.

The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system.

The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain.

Refer to the J 43600 ACR 2000 manual for operation and setup instruction. See Special Tools . Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount.

A/C Refrigerant System Oil Charge Replenishing

If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 . See Special Tools . For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities .

Balancing Procedure

1. Before installing the compressor, the refrigerant oil will have to be fully drained.
2. Add back the same quantity of polyalkylene glycol (PAG) oil as drained from the removed compressor. Refer to the amount of refrigerant oil recorded during the compressor removal.

Tools Required

J 39400-A Halogen Leak Detector. See Special Tools .

J 39400-A Halogen Leak Detector. See Special Tools .

J 39400-A Halogen Leak Detector. See Special Tools .

J 39400-A Halogen Leak Detector. See Special Tools .

J 39400-A Halogen Leak Detector. See Special Tools .

J 39400-A Halogen Leak Detector. See Special Tools .

J 39400-A Halogen Leak Detector. See Special Tools .

J 39400-A Halogen Leak Detector. See Special Tools .

J 39400-A Halogen Leak Detector. See Special Tools .

J 43181 Heater Line QC Release Tool