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HVAC Discuss Heating, Ventilation & Air Conditioning related issues on Duramax equipped trucks.

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Old 06-26-2019, 04:12 AM   #11 (permalink)
DTMACajun
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This is the only real snag I ran into.....the orifice tube.

On my K5's OEM liquid line/evap assembly, the orifice tube was located differently than on the S10 evap. I'm not even going to try and explain the technicalities here, but the jist of the situation is that I found myself in a predicament where the orifice tube inlet filter screen didn't fit into the K5's liquid line. Soooooo......I modified the orifice tube.

As seen in the pics, I cut off most of the orifice tube's inlet filter screen. The orifice tube does have filter screens on both sides (inlet and outlet), so there is still a barrier for catching debris within the refrigerant stream.

Once cut off, the orifice tube was able to be inserted and the liquid line-to-evap inlet fitting made up without further interference.

Attached Images
File Type: jpg 20190616_091319_1561536681654.jpg (34.4 KB, 3 views)
File Type: jpg 20190616_091235_1561536708075.jpg (43.2 KB, 3 views)
__________________
- '82 K5 Blazer, '97 6.5L (506 block) swapped
- DB2-4911 IP, 3/8" inlet fitting, 1/4 open on adjustment screw, FFM removed
- Leroy DB2 timekeeper IP gear set
- Carter 4601 LP w/ 3123 pre-filter, tank sock deleted
- Holset HX35, Leroy boost bolt, PTW downpipe adapter, Kinugawa actuator w/ 15psi spring
- ARP head studs, +.010" Cometic head gaskets, sleeved coolant passages between valves
- HO water pump, dual 195-degree T-stats, Leroy bypass fitting, Duramax fan, Hayden 2839 fan clutch, KKS 1492 radiator, Shell ELC coolant, Royal Purple "Ice" coolant additive
- Energy Suspension polyurethane engine mounts
- 4" DE exhaust (no muffler), w/ DE 2.5" crossover
- Fluidampr harmonic balancer, Leroy SS oil cooler lines/fittings
- Autometer fuel psi, boost psi, pyrometer, Leroy fuel gauge isolator
- K47 airbox
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Old 06-26-2019, 04:18 AM   #12 (permalink)
DTMACajun
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I added 8oz of ACDelco 15-118 refrigerant oil to each of the following:

2.5oz into the drier/accumulator inlet
2.0oz into the evaporator inlet
2.5oz into the compressor inlet
.5oz into the liquid line
.5oz into the vapor line

Since I retained my original condenser and knew that it already had oil in it, I did not add any oil to the condenser.

Attached Images
File Type: jpg 20190616_093140_1561536825277.jpg (48.9 KB, 2 views)
__________________
- '82 K5 Blazer, '97 6.5L (506 block) swapped
- DB2-4911 IP, 3/8" inlet fitting, 1/4 open on adjustment screw, FFM removed
- Leroy DB2 timekeeper IP gear set
- Carter 4601 LP w/ 3123 pre-filter, tank sock deleted
- Holset HX35, Leroy boost bolt, PTW downpipe adapter, Kinugawa actuator w/ 15psi spring
- ARP head studs, +.010" Cometic head gaskets, sleeved coolant passages between valves
- HO water pump, dual 195-degree T-stats, Leroy bypass fitting, Duramax fan, Hayden 2839 fan clutch, KKS 1492 radiator, Shell ELC coolant, Royal Purple "Ice" coolant additive
- Energy Suspension polyurethane engine mounts
- 4" DE exhaust (no muffler), w/ DE 2.5" crossover
- Fluidampr harmonic balancer, Leroy SS oil cooler lines/fittings
- Autometer fuel psi, boost psi, pyrometer, Leroy fuel gauge isolator
- K47 airbox
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Old 06-26-2019, 04:23 AM   #13 (permalink)
DTMACajun
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The '82 compressor wiring plug (in hand) did not attach to the '97 compressor, so I cut it off and wired in the appropriate plug (part# PT-209).

New plug's positive wire attaches to the light green wire from the evap pressure switch, and the negative wire goes to ground!
Attached Images
File Type: jpg 20190619_160849_1561537192471.jpg (42.3 KB, 3 views)
__________________
- '82 K5 Blazer, '97 6.5L (506 block) swapped
- DB2-4911 IP, 3/8" inlet fitting, 1/4 open on adjustment screw, FFM removed
- Leroy DB2 timekeeper IP gear set
- Carter 4601 LP w/ 3123 pre-filter, tank sock deleted
- Holset HX35, Leroy boost bolt, PTW downpipe adapter, Kinugawa actuator w/ 15psi spring
- ARP head studs, +.010" Cometic head gaskets, sleeved coolant passages between valves
- HO water pump, dual 195-degree T-stats, Leroy bypass fitting, Duramax fan, Hayden 2839 fan clutch, KKS 1492 radiator, Shell ELC coolant, Royal Purple "Ice" coolant additive
- Energy Suspension polyurethane engine mounts
- 4" DE exhaust (no muffler), w/ DE 2.5" crossover
- Fluidampr harmonic balancer, Leroy SS oil cooler lines/fittings
- Autometer fuel psi, boost psi, pyrometer, Leroy fuel gauge isolator
- K47 airbox

Last edited by DTMACajun; 06-26-2019 at 04:32 AM.
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Old 06-26-2019, 04:36 AM   #14 (permalink)
DTMACajun
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After evacuating and leak-test, it took a few tries/experimenting to get the R-134A refrigerant charge pressures correct but we settled on 2.25oz for the final charge.
__________________
- '82 K5 Blazer, '97 6.5L (506 block) swapped
- DB2-4911 IP, 3/8" inlet fitting, 1/4 open on adjustment screw, FFM removed
- Leroy DB2 timekeeper IP gear set
- Carter 4601 LP w/ 3123 pre-filter, tank sock deleted
- Holset HX35, Leroy boost bolt, PTW downpipe adapter, Kinugawa actuator w/ 15psi spring
- ARP head studs, +.010" Cometic head gaskets, sleeved coolant passages between valves
- HO water pump, dual 195-degree T-stats, Leroy bypass fitting, Duramax fan, Hayden 2839 fan clutch, KKS 1492 radiator, Shell ELC coolant, Royal Purple "Ice" coolant additive
- Energy Suspension polyurethane engine mounts
- 4" DE exhaust (no muffler), w/ DE 2.5" crossover
- Fluidampr harmonic balancer, Leroy SS oil cooler lines/fittings
- Autometer fuel psi, boost psi, pyrometer, Leroy fuel gauge isolator
- K47 airbox
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Old 06-26-2019, 04:51 AM   #15 (permalink)
DTMACajun
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Location: Gray, LA
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In summary, it took a little trial-and-error along with a bit of customization but I was able to successfully accomplish the S10 box mod and get my A/C going! It wasn't as difficult to perform as initially expected, and overall went relatively smooth.

I'm satisfied with the box/mod result, but realized afterwards that I also need to replace the original condenser. It's the old tube-and-fin type for R12 and does a mediocre job of sufficiently cooling R-134A. My A/C performance is ok, but it can definitely be better....so I'll soon be replacing the condenser with an ACDelco 15-6960, which is a retrofit parallel-flow condenser for square-body GM's that were converted over to R-134A. Once I've swapped it over, I'll report the results.
__________________
- '82 K5 Blazer, '97 6.5L (506 block) swapped
- DB2-4911 IP, 3/8" inlet fitting, 1/4 open on adjustment screw, FFM removed
- Leroy DB2 timekeeper IP gear set
- Carter 4601 LP w/ 3123 pre-filter, tank sock deleted
- Holset HX35, Leroy boost bolt, PTW downpipe adapter, Kinugawa actuator w/ 15psi spring
- ARP head studs, +.010" Cometic head gaskets, sleeved coolant passages between valves
- HO water pump, dual 195-degree T-stats, Leroy bypass fitting, Duramax fan, Hayden 2839 fan clutch, KKS 1492 radiator, Shell ELC coolant, Royal Purple "Ice" coolant additive
- Energy Suspension polyurethane engine mounts
- 4" DE exhaust (no muffler), w/ DE 2.5" crossover
- Fluidampr harmonic balancer, Leroy SS oil cooler lines/fittings
- Autometer fuel psi, boost psi, pyrometer, Leroy fuel gauge isolator
- K47 airbox
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Old 06-26-2019, 08:29 AM   #16 (permalink)
OkDually
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Great write up on the mod!

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1996 K3500 6.5L,( "F" Eng #141 cast block) 5 speed manual, crewcab, dually longbed: 208,000mi.
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AirDog II DF165 w/ tank sock delete - XDP
TD-Max boost controller - Kennedy Diesel
OPS extension hose - Leroy Diesel
Glow Plug Harness- PT Wiring Solutions
Glowshift Maxtow EGT,Boost, Fuel gauges
Boost & Fuel Pressure Bolts - Leroy Diesel
2/0 Battery Cable Upgrade - PT Wiring Solutions
PMD w/#9 resistor and Re-Location Kit, mounted to bumper - Leroy Diesel
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OptiLube summer + Formula


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Old 06-26-2019, 09:52 AM   #17 (permalink)
heymccall
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Should be 2.25lb for the charge quantity, not 2.25oz.
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Old 06-27-2019, 02:13 AM   #18 (permalink)
DTMACajun
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Quote:
Originally Posted by heymccall View Post
Should be 2.25lb for the charge quantity, not 2.25oz.
You are correct sir, my mistake! 2.25lbs was the R-134A charge, not 2.25oz.

Sure wish DP allowed us to edit our posts, I'd go back and fix it
__________________
- '82 K5 Blazer, '97 6.5L (506 block) swapped
- DB2-4911 IP, 3/8" inlet fitting, 1/4 open on adjustment screw, FFM removed
- Leroy DB2 timekeeper IP gear set
- Carter 4601 LP w/ 3123 pre-filter, tank sock deleted
- Holset HX35, Leroy boost bolt, PTW downpipe adapter, Kinugawa actuator w/ 15psi spring
- ARP head studs, +.010" Cometic head gaskets, sleeved coolant passages between valves
- HO water pump, dual 195-degree T-stats, Leroy bypass fitting, Duramax fan, Hayden 2839 fan clutch, KKS 1492 radiator, Shell ELC coolant, Royal Purple "Ice" coolant additive
- Energy Suspension polyurethane engine mounts
- 4" DE exhaust (no muffler), w/ DE 2.5" crossover
- Fluidampr harmonic balancer, Leroy SS oil cooler lines/fittings
- Autometer fuel psi, boost psi, pyrometer, Leroy fuel gauge isolator
- K47 airbox
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Old 06-27-2019, 02:32 AM   #19 (permalink)
OkDually
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Quote:
Originally Posted by DTMACajun View Post
You are correct sir, my mistake! 2.25lbs was the R-134A charge, not 2.25oz.

Sure wish DP allowed us to edit our posts, I'd go back and fix it
IIRC, there is a 30 minute time limit on editing.
Anything beyond that staff can go in and edit for you.
Just click on the little red triangle below the username in the post and tell staff what is needed.

__________________
1996 K3500 6.5L,( "F" Eng #141 cast block) 5 speed manual, crewcab, dually longbed: 208,000mi.
Diamond Eye 4" Turbo Back Exhaust w/2.5" Flo-Pro Crossover
AirDog II DF165 w/ tank sock delete - XDP
TD-Max boost controller - Kennedy Diesel
OPS extension hose - Leroy Diesel
Glow Plug Harness- PT Wiring Solutions
Glowshift Maxtow EGT,Boost, Fuel gauges
Boost & Fuel Pressure Bolts - Leroy Diesel
2/0 Battery Cable Upgrade - PT Wiring Solutions
PMD w/#9 resistor and Re-Location Kit, mounted to bumper - Leroy Diesel
GM-5 Turbocharger
4.10 gear ratio
OptiLube summer + Formula


Proud member #1039 of The 3500 Dually Club

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Old 07-19-2019, 09:00 AM   #20 (permalink)
DTMACajun
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FINALLY have respectable A/C performance! Quite a few changes from what's been done previously though.

First, I went ahead with the condenser swap, but used an ADPI 7013642 instead of the previously-mentioned ACDelco 15-6960. The ADPI is a true parallel-flow style condenser while the ACDelco is a picollo-style/6mm, of which the parallel-flow style is the most efficient for cooling R-134A so it made sense to go this route. The ADPI was also significantly cheaper at $84, versus $220 for the Delco. Condenser swap was fairly straight-forward....I removed the bracketry from my OEM condenser and installed them on the ADPI, but had to drill new holes in the brackets so it would align with the original mounting holes on the vehicle. Additionally, I added 2oz. of refrigerant oil to the new condenser, then re-charged the system with 2.3lbs of R-134.

Second, I replaced my modified white Chevrolet-style orifice tube with an unmodified Ford blue orifice tube (the blue tube has a slightly smaller orifice than the white tube, and I've read several times that it can help to produce cooler temps so I decided to give it a try). In doing so, I realized that I never needed to cut off the inlet screen on the white tube, as seen in my pics. I simply didn't push down hard enough on the white tube while trying to install it into the evaporator inlet line, which led me to believe that it wouldn't insert into the line and is why I cut the inlet screen off. Anyway, the inlet pressure had seated the white tube into place where it should've been, so I blew it out by applying compressed air on the outlet line and then installed the blue tube without further issue.

Next, inside the HVAC box inside of the cab I found the blend door partially hung open, which was allowing some heater core air to mix with the evaporator air. As a quick fix, I tie-wired the door shut. This made a very noticeable difference in vent temps!

Finally, the biggest issue...the outside air recirculation door/vent was MISSING...apparently removed by the previous owner during re-painting maybe, I'm not sure. Anyway, I temporarily crammed rags into the hole to block it off, allowing the blower motor to begin re-circulating the cooler cab air...and the vent temps got much cooler!

With outside temps hanging out in the mid/upper 90's, I'm getting low 50's at the vents now. During the evening when it's around low 80's outside, I've seen 39 at the vents. HUGE difference in what I had versus what I have now! So glad that it's finally come together and is working beyond expectation. So, there it is....good luck to any and all who decide to go this route, and hope that this thread has been beneficial!

__________________
- '82 K5 Blazer, '97 6.5L (506 block) swapped
- DB2-4911 IP, 3/8" inlet fitting, 1/4 open on adjustment screw, FFM removed
- Leroy DB2 timekeeper IP gear set
- Carter 4601 LP w/ 3123 pre-filter, tank sock deleted
- Holset HX35, Leroy boost bolt, PTW downpipe adapter, Kinugawa actuator w/ 15psi spring
- ARP head studs, +.010" Cometic head gaskets, sleeved coolant passages between valves
- HO water pump, dual 195-degree T-stats, Leroy bypass fitting, Duramax fan, Hayden 2839 fan clutch, KKS 1492 radiator, Shell ELC coolant, Royal Purple "Ice" coolant additive
- Energy Suspension polyurethane engine mounts
- 4" DE exhaust (no muffler), w/ DE 2.5" crossover
- Fluidampr harmonic balancer, Leroy SS oil cooler lines/fittings
- Autometer fuel psi, boost psi, pyrometer, Leroy fuel gauge isolator
- K47 airbox

Last edited by DTMACajun; 07-19-2019 at 09:05 AM.
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