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

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Old 06-26-2019, 02:02 AM   #1 (permalink)
DTMACajun
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S10 A/C box mod re-visited

After recently swapping a '97 6.5L TD engine into my '82 K5 Blazer (originally 6.2L-powered), I realized that the 6.5L engine's turbocharger occupies the same space as my K5's blower/evap box. I hadn't anticipated this issue prior to the swap, but after discovering it I figured that someone must surely know a way to work around it.

After searching, I found DP member Diaric's thread here -> https://www.dieselplace.com/forum/63.../topics/465004 which explains the solution. Many thanks to Diaric and the previous members for their information; I couldn't have done it without you guys! However, I'm a stickler for details and felt as though Diaric's post was a bit vague. So, I decided to combine the information learned in his thread with my own and create this thread. Hopefully, our combined knowledge should remove much of the guesswork for future enthusiasts!

__________________
- '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, 02:35 AM   #2 (permalink)
DTMACajun
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Location: Gray, LA
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For my specific application, these were the items that were either replaced and/or modified, along with their respective price.

ACDelco 15-22124A compressor (reman). $209
Four Seasons 55909 A/C hose assy. $60
Four Seasons 54520 evap core. $57
Four Seasons 33183 drier/accumulator. $14
1992 S10 blower/evap box. $50 (junkyard)
ACDelco 15-118 refrigerant oil. $18
Hose assy. modification at local hose shop. $175
Bond-o fiberglass repair kit. $20
Evacuate, leak-check, and 2.25oz. charge of R-134A. Free to me, but usually around $100
VDO PM-129 blower motor. $45
Four Seasons 35777 HVAC relay. $12

With the exception of the blower motor and relay, you will need all of the above to successfully perform the project. I accidentally fried my HVAC relay, and my blower motor was tired so I just went ahead and replaced both but you can use your OEM stuff provided that they're working.

__________________
- '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, 02:43 AM   #3 (permalink)
DTMACajun
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Join Date: May 2016
Location: Gray, LA
Posts: 63
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As you can see by the two pictures here, the S10 box (darker black on the right) and K5 box (lighter black/grayish on the left) are largely similar in appearance, but each points the evaporator core in opposing directions....when installed, the S10 evap points to the passenger fender, and the K5 evap points to the engine.

Since the K5's evap box and 6.5L turbo occupy the same space within the engine compartment, the objective here is to cut each box in half and then graft the S10 evap box onto the K5 blower box.
Attached Images
File Type: jpg 20190606_122321_1561531079913.jpg (37.0 KB, 3 views)
File Type: jpg 20190606_122343_1561531106982.jpg (61.9 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, 02:47 AM   #4 (permalink)
DTMACajun
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Join Date: May 2016
Location: Gray, LA
Posts: 63
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This picture shows where I cut the S10 box. The blower housing will not be used, so I made my cut fairly close to it so that there was plenty of evap box to initially work with. Although the evap box was further trimmed down later on, it's a good idea to ensure that you've not cut too much off in the initial cut!
Attached Images
File Type: jpg 20190606_125751_1561531494361.jpg (36.8 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, 02:52 AM   #5 (permalink)
DTMACajun
Clutch
 
Join Date: May 2016
Location: Gray, LA
Posts: 63
iTrader Score: 0 reviews

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Louisiana Diesel Truck Association Member

This picture shows where I cut the K5 blower box. Since the evap box will not be used, I left plenty of extra blower box to initially work with. It was also further trimmed down later on.
Attached Images
File Type: jpg 20190606_130627_1561531732187.jpg (37.9 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, 03:01 AM   #6 (permalink)
DTMACajun
Clutch
 
Join Date: May 2016
Location: Gray, LA
Posts: 63
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Louisiana Diesel Truck Association Member

Here's the S10 evap box and K5 blower housing prior to grafting.

Prior to cutting the K5 box, I traced an outline of it on the wooden work table (look closely, you can see the Sharpie outline on the wood). I used this outline as a rough guide for where to make the final trim/cuts on BOTH boxes for alignments purposes. Although the S10 evap box's original mounting bolt holes will not line up with the K5's, it's very important to ensure that the evap core housing is properly located (over the cabin inlet hole). It's a close fit, only about 1" margin for error....so on your traced template, be sure that the S10 evap box is dimensionally very close to the K5's outline.
Attached Images
File Type: jpg 20190606_135207_1561531989296.jpg (40.0 KB, 3 views)
File Type: jpg 20190606_135223_1561532027348.jpg (39.9 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, 03:09 AM   #7 (permalink)
DTMACajun
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Join Date: May 2016
Location: Gray, LA
Posts: 63
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My K5's blower box was all fiberglass, but the S10's box was plastic. Fiberglass doesn't like to adhere very well to smooth plastic, so I scuffed the plastic up very well with 80-grit sandpaper prior to laying the first layers. In these pictures, I've only got one or two layers adhered but in total, I applied three layers to the outside and inside of the box.
Attached Images
File Type: jpg 20190609_154815_1561532618603.jpg (40.2 KB, 3 views)
File Type: jpg 20190609_154906_1561532651710.jpg (33.6 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, 03:13 AM   #8 (permalink)
DTMACajun
Clutch
 
Join Date: May 2016
Location: Gray, LA
Posts: 63
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Louisiana Diesel Truck Association Member

Just prior to fiberglassing, I installed both pieces to verify proper alignment and fit. As you can see, its a tight fit....but it clears the turbo!
Attached Images
File Type: jpg 20190606_145052_1561533036545.jpg (44.1 KB, 3 views)
File Type: jpg 20190606_145019_1561533088618.jpg (39.9 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, 03:18 AM   #9 (permalink)
DTMACajun
Clutch
 
Join Date: May 2016
Location: Gray, LA
Posts: 63
iTrader Score: 0 reviews

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Louisiana Diesel Truck Association Member

My K5's blower motor resistor easily transferred over to the S10 evap box after a small trim job to the S10's resistor hole. Look closely at the pic for the Sharpie marks highlighting the area needing trimmed for the resistor to properly fit.
Attached Images
File Type: jpg 20190610_074511(0)_1561533342680.jpg (33.7 KB, 3 views)
File Type: jpg 20190610_074547_1561533372180.jpg (27.8 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 03:19 AM.
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Old 06-26-2019, 03:46 AM   #10 (permalink)
DTMACajun
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Join Date: May 2016
Location: Gray, LA
Posts: 63
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This is where the fun begins 🙄

I followed Diaric's lead by using an '92 S10 evap core, but had to closely observe his pictures to figure out that he used an '87 R20 6.2L drier/accumulator. He initially tried using a '94 S10 accumulator, but had trouble getting it to work because of the inlet/outlet locations so he used an '87 R20 accumulator instead.

Anyway, the '87 R20 accumulator bolts right up to the '92 S10 evap. However, the '97 A/C hose assembly does not attach to the '87 R20 accumulator, nor does the '97 hose assembly attach to an '82 K5 condenser. Luckily my K5's OEM A/C hose assembly did attach to the '87 accumulator, so I took both hose assemblies to a local hose repair shop and had them modify the '97 hose assembly with the fittings from my '82 hose assembly. Although a bit expensive, the shop did a fantastic job!

The condenser outlet-to-evap inlet line (liquid refrigerant line) is the original from my '82 K5. It attached to the '92 S10 evap without issue, but I did have to straighten the line out from it's original bend configuration and custom-bend it to make it reach the condenser once attached to the evaporator. Additionally, I also had to tweak the condenser's outlet line a bit to make up the last inch that I couldn't get from the liquid line.

Attached Images
File Type: jpg 20190616_091514_1561533667482.jpg (39.1 KB, 3 views)
File Type: jpg 20190616_091625_1561533686674.jpg (58.3 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
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