Heating, Ventilation and Air Conditioning: Other Chevrolet Silverado 3500

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 .
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 fluorescent dye cleaner J 43872 .

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 .

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 .

Defrosting Insufficient

Defrosting Insufficient

High or Low Mode Control Effort

High or Low Mode Control Effort

High or Low Temperature Control Effort

High or Low Temperature Control Effort

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 and Equipment»(ref-184172-S42637868852005082200000) .
2. J 45037 A/C Oil Injector. See «Special Tools and Equipment»(ref-184172-S42637868852005082200000) .

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. 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. 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 . For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities .

Balancing

1. The replacement compressor is shipped with 240 ml (8.0 oz) of refrigerant oil.
2. Before installing the compressor, the refrigerant oil will have to be fully drained.
3. Add back the same quantity of 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 and Equipment .

Scheme 88

Scheme 89

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
2. Remove the intake air resonator replacement. Refer to «Intake Air Resonator Replacement»(ref-184137-S05331089022005082200000) in Engine Controls - 8.1L.
3. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening.
4. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt.
5. Remove the A/C belt from the A/C compressor.
6. Slowly release the tension on the A/C belt tensioner.
7. Remove the discharge hose bolt from the A/C compressor.
8. Remove the discharge hose from the A/C compressor.
9. Remove the suction hose bolt from the A/C compressor.
10. Remove the suction hose from the A/C compressor.
11. Discard the sealing washers. Cap all of the openings.
12. Disconnect the electrical connections.
13. Remove the A/C compressor mounting bolts.
14. Remove the A/C compressor (2) from the bracket (1).
15. If replacing the A/C compressor. Refer to «Compressor Oil Balancing»(ref-184172-S15883091112005082200000) .

J 39400-A alogen Leak Detector. See Special Tools and Equipment .

Scheme 90

Scheme 91

Scheme 92

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
2. Install a ratchet into the belt tensioner adapter opening.
3. Rotate the belt tensioner counterclockwise in order to relieve the tension on the belt.
4. Remove the belt from the A/C compressor.
5. Slowly release the tension on the belt tensioner.
6. Remove the discharge hose bolt (2) from the A/C compressor (3).
7. Remove the discharge hose (1) from the A/C compressor (3).
8. Remove the suction hose bolt (2) from the A/C compressor (3).
9. Remove the suction hose (1) from the A/C compressor (3).
10. Discard the sealing washers. Cap all of the openings.
11. Disconnect the electrical connections.
12. Remove the A/C compressor mounting bolts.
13. If replacing the A/C compressor. Refer to «Compressor Oil Balancing»(ref-184172-S15883091112005082200000) .

Scheme 93

1. Remove the caps or tape from the hose and line ends.
2. Install the A/C compressor.
3. Install the A/C compressor mounting bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
4. Connect the electrical connection.
5. Install the A/C discharge hose (1) to the compressor (3) using new sealing washers.
6. Install the A/C discharge hose bolt (2) to the A/C compressor (3). Tighten: Tighten the bolt to 16 N.m (12 lb ft).
7. Install the A/C suction hose (1) to the compressor (3) using new sealing washers.
8. Install the A/C suction hose bolt (2) to the A/C compressor (3). Tighten: Tighten the bolt to 16 N.m (12 lb ft).
9. Install the drive belt. Refer to «Drive Belt Replacement»(ref-184191-S24246726742005082200000) in Engine Mechanical - 6.6L.
10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
11. Leak test the fittings of the component using the J 39400-A .

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

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

Scheme 94

Scheme 95

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
2. Remove the discharge hose mounting bolt (2) from the A/C compressor. Discard the bolt.
3. Remove the discharge hose (5) from the A/C compressor.
4. Remove the upper radiator air baffle. Refer to «Radiator Air Baffle and Deflector Replacement - Upper»(ref-184167-S28062100682005082200000) in Engine Cooling.
5. Remove the discharge hose nut from the condenser. Discard the nut.
6. Remove the discharge hose from the condenser.
7. Disconnect the A/C recirculation switch from the discharge hose.
8. Remove the discharge hose from the vehicle.
9. Discard all of the used sealing washers. Cap the system openings.

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

Scheme 96

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
2. Remove the discharge hose mounting bolt (2) from the A/C compressor.
3. Remove the discharge hose (1) from the A/C compressor.
4. Remove the upper radiator baffle. Refer to «Radiator Air Baffle and Deflector Replacement - Upper»(ref-184167-S28062100682005082200000) in Engine Cooling.
5. Remove the discharge hose nut from the condenser.
6. Remove the discharge hose from the condenser.
7. Disconnect the electrical connector from the A/C recirculation switch.
8. Remove the discharge hose from the vehicle.
9. Discard all of the used sealing washers. Cap the system openings.

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

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

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

Scheme 97

Scheme 98

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
2. Remove the evaporator tube nut from the evaporator.
3. Remove the evaporator tube from the evaporator.
4. Remove the right park/turn signal lamp. Refer to «Park/Turn Signal Lamp Replacement (Old Style)»(ref-184117-S17387384182005082200000) .
5. Remove the grille from the vehicle. Refer to «Grille Replacement (GMC)»(ref-184169-S17598306392005082200000) or «Grille Replacement (Chevrolet)»(ref-184169-S35473267962005082200000) .
6. Remove the evaporator tube nut from the condenser.
7. Remove the evaporator tube from the condenser.
8. Remove the evaporator tube from the vehicle.
9. Discard all of the used sealing washers. Cap all of the open connections.

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

Scheme 99

Scheme 100

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
2. Remove the evaporator tube nut from the evaporator.
3. Remove the evaporator tube from the evaporator.
4. Loosen the nut from the evaporator tube fitting.
5. Remove the rear evaporator tube (3) from the vehicle.
6. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-184136-S32591068062005082200000) in Engine Controls - 5.3L.
7. Remove the push pin from the right side radiator air baffle.
8. Remove the bolts (2) from the starter/generator control module (SGCM) coolant pump (1).
9. Reposition the SGCM coolant pump.
10. Remove the right park/turn signal lamp. Refer to «Park/Turn Signal Lamp Replacement (Old Style)»(ref-184117-S17387384182005082200000) .
11. Remove the grille from the vehicle. Refer to «Grille Replacement (GMC)»(ref-184169-S17598306392005082200000) or «Grille Replacement (Chevrolet)»(ref-184169-S35473267962005082200000) .
12. Remove the evaporator tube nut from the condenser.
13. Remove the evaporator tube from the condenser.
14. Remove the front evaporator tube from the vehicle.
15. Discard all of the used sealing washers. Cap all of the open connections.

Scheme 101

1. Install the front evaporator tube to the vehicle.
2. Uncap all of the open connections
3. Install the evaporator tube to the condenser using new sealing washers. Refer to «Sealing Washer Replacement»(ref-184172-S36685995572005082200000) .
4. Install the evaporator tube nut to the condenser. Tighten: Tighten the nut to 16 N.m (12 lb ft).
5. Install the grille to the vehicle. Refer to «Grille Replacement (GMC)»(ref-184169-S17598306392005082200000) or «Grille Replacement (Chevrolet)»(ref-184169-S35473267962005082200000) .
6. Install the right park/turn signal lamp. Refer to «Park/Turn Signal Lamp Replacement (Old Style)»(ref-184117-S17387384182005082200000) .
7. Position the SGCM coolant pump (1) to the radiator core support (3).
8. Install the bolts (2) to the SGCM coolant pump (1). Tighten: Tighten the nut to 16 N.m (12 lb ft).
9. Install the push pin to the right side radiator air baffle.
10. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-184136-S32591068062005082200000) in Engine Controls - 5.3L.
11. Install the rear evaporator tube (3) to the vehicle.
12. Connect the nut to the evaporator tube fitting. Tighten: Tighten the nut to 9 N.m (80 lb in).
13. Install the evaporator tube to the evaporator.
14. Install the evaporator tube nut to the evaporator. Tighten: Tighten the nut to 16 N.m (12 lb ft).
15. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
16. Leak test the fittings of the components using the J 39400-A . See «Special Tools and Equipment»(ref-184172-S42637868852005082200000) .

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

J 39400-A alogen Leak Detector. See Special Tools and Equipment .

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

Scheme 102

Scheme 103

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
2. Remove the grille. Refer to «Grille Replacement (GMC)»(ref-184169-S17598306392005082200000) or «Grille Replacement (Chevrolet)»(ref-184169-S35473267962005082200000) in Exterior Trim.
3. Remove the tie bar to radiator brace bolts (1). Access the bolts from the rear of the upper radiator support.
4. Remove the lower bolts from the hood latch support bracket.
5. Remove the compressor discharge hose assembly bolt from the condenser.
6. Disconnect the compressor discharge hose assembly from the condenser.
7. Remove the evaporator tube nut from the condenser.
8. Disconnect the evaporator tube from the condenser.
9. Remove the insulator retainer bolts and the upper insulator retainers.
10. Remove the condenser from the vehicle.

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

Scheme 104

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(ref-184172-S07266075792005082200000) .
2. Remove the evaporator tube nut from the evaporator.
3. Remove the evaporator tube from the evaporator.
4. Remove the nut from the evaporator tube (3).
5. Disconnect the electrical connector from the A/C low pressure switch.
6. Remove the compressor hose nut from the accumulator.
7. Remove the compressor hose from the accumulator.
8. Remove the nut (2) from the evaporator fitting.
9. Remove the accumulator bracket nut (4) from the retaining stud.
10. Remove the accumulator (3).
11. Remove the retaining bracket bolt (5).
12. Remove the retaining bracket (6) from the accumulator.
13. Remove and discard the O-ring seals.

J 43181 Quick Connect Connector Removal Tool

J 43181 Quick Connect Connector Removal Tool. See Special Tools and Equipment .

Scheme 105

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
2. Remove the air intake tube.
3. Remove the heater and surge tank hose from the mounting clip.
4. Using the J 43181 disconnect the heater hose from the heater core inlet. Install the J 43181 to the heater core pipe. Close the tool around the heater core pipe. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
5. Remove the inlet heater hose (1) from the engine coolant inlet fitting.
6. Remove the inlet heater hose.

J 43181 Quick Connect Connector Removal Tool. See Special Tools and Equipment .

Scheme 106

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
2. Remove the air intake tube.
3. Remove the heater and surge tank hose from the mounting clip.
4. Using the J 43181 disconnect the heater hose from the heater core inlet. Install the J 43181 to the heater core pipe. Close the tool around the heater core pipe. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
5. Reposition the inlet heater hose clamp from the engine coolant outlet.
6. Remove the inlet heater hose (1) from the engine coolant outlet.
7. Remove the auxiliary inlet heater hose if equipped.
8. Remove the inlet heater hose.

J 43181 Quick Connect Connector Removal Tool

J 43181 Quick Connect Connector Removal Tool

Scheme 107

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
2. Remove the air intake tube.
3. Using the J 43181 disconnect the heater hose from the heater core inlet. Install the J 43181 to the heater core pipe. Close the tool around the heater core pipe. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
4. Reposition the inlet heater hose clamp from the engine.
5. Remove the inlet heater hose from the engine.
6. Remove the inlet heater hose mounting bolt.
7. Remove the inlet heater hose from the engine.
8. Remove the inlet heater hose.

Scheme 108

1. Install the inlet heater hose.
2. Install the inlet heater hose to the engine.
3. Reposition the inlet heater hose clamp to the engine.
4. Install the inlet heater hose mounting bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
5. Install the inlet heater hose to the engine.
6. Connect the heater hoses to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
7. Install the air intake tube.
8. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.

Scheme 109

Scheme 110

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
2. Loosen the air cleaner outlet duct clamps at the following locations: Throttle body Mass airflow/intake air temperature (MAF/IAT) sensor
3. Remove the radiator inlet hose clip from the outlet duct.
4. Remove the air cleaner outlet duct.
5. Reposition the inlet heater hose clamp from the engine.
6. Remove the inlet heater hose from the engine.
7. Reposition the inlet heater hose clamp (4) from the auxiliary water pump (1).
8. Remove the inlet heater hose (6) from the auxiliary water pump (1).

J 43181 Quick Connect Connector Removal Tool

J 43181 Quick Connect Connector Removal Tool

J 43181 Quick Connect Connector Removal Tool

J 43181 Quick Connect Connector Removal Tool

J 43181 Quick Connect Connector Removal Tool.

Scheme 111

Scheme 112

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .
2. Remove the radiator outlet hose from the radiator. Refer to «Radiator Hose Quick Connect Fitting»(ref-184167-S30999457252005082200000) .
3. Using the J 43181 disconnect the heater hoses from the heater core outlet. Install the J 43181 to the heater core pipe. Close the tool around the heater core pipe. Firmly pull the tool into the quick connect end of the heater hose. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the hose from the heater core.
4. Reposition the surge tank outlet hose clamp at the surge tank.
5. Remove the surge tank outlet hose (2) from the surge tank.
6. Reposition the outlet hose clamp the water pump.
7. Remove the outlet hose from the water pump.

Scheme 113

1. Install the outlet hose to the water pump.
2. Position the outlet hose clamp to the water pump.
3. Install the surge tank outlet hose (2) from the surge tank.
4. Position the surge tank outlet hose clamp to the surge tank.
5. Connect the heater and surge tank hoses to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click.
6. Install the radiator outlet hose to the radiator. Refer to «Radiator Hose Quick Connect Fitting»(ref-184167-S30999457252005082200000) .
7. Fill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) .