Rocket Man's 02 Denali Build Thread AKA "THE BEAST"

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RAMurphy

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So I did some disassembling and flushing this morning. Didn’t spend a lot of time on it after my initial flush incident. I started by doing the evaporator and had no idea that it was gonna blast right back at me out the opposing hole with so much force. It hit me in the face and went all over that side of the engine bay. Good news is it looks like a good degreaser but bad news it stings in the eyes. I regrouped and rigged 2 different size drain hoses and finished the evaporator. I blew it out with air afterwards. The fluid has some microscopic silver metal, super fine. It’s coming out clear after the flush.

I started to flush the lines I removed and noticed the evaporator line has been rubbing on the frame for some reason. It’s not leaking and might be ok to reuse but I’d feel better replacing it. It would suck if it started leaking in a year after all I’m doing to the AC. I ordered a new OEM one off Amazon. It won’t be here until Friday so now I have all kinds of time to get this done. :p

My eye is stinging so I’m on break until further notice. ;)

Required compressor pic attached.
Sorry about the slight mishap. That most likely happened to me too, but that was a long time ago and I have forgotten so much in the past ten years. Good luck as you press forward.
 
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Rocket Man

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Great news. Just ensure that you are confident you blew out all the flushing agent and it is dried out. Like I said, I spent extra time on the evaporators.
It will be sitting for a few days waiting on parts so it should dry out especially considering it’s gonna be close to 100 a couple days. I blew it out real good, I have a 25 gallon compressor.
 
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Rocket Man

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Installed the condenser, perfect fit. There’s so much going on there with the intercooler, condenser, oil cooler and radiator. Good thing the trans cooler got moved down behind the lower bumper opening.
 

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randeez

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So I did some disassembling and flushing this morning. Didn’t spend a lot of time on it after my initial flush incident. I started by doing the evaporator and had no idea that it was gonna blast right back at me out the opposing hole with so much force. It hit me in the face and went all over that side of the engine bay. Good news is it looks like a good degreaser but bad news it stings in the eyes. I regrouped and rigged 2 different size drain hoses and finished the evaporator. I blew it out with air afterwards. The fluid has some microscopic silver metal, super fine. It’s coming out clear after the flush.

I started to flush the lines I removed and noticed the evaporator line has been rubbing on the frame for some reason. It’s not leaking and might be ok to reuse but I’d feel better replacing it. It would suck if it started leaking in a year after all I’m doing to the AC. I ordered a new OEM one off Amazon. It won’t be here until Friday so now I have all kinds of time to get this done. :p

My eye is stinging so I’m on break until further notice. ;)

Required compressor pic attached.

i ordered the same flush kit, so hopefully ill have just as good of luck

where did you find a green ac belt? are you using the stretch belt or with the tensioner? (i just wanted to match the reg belt not really a huge deal)

ordered new driers for mine (for cab and chiller) and a new orifice tube also...should have prob done so before running with new compressor but o wel
 
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Rocket Man

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i ordered the same flush kit, so hopefully ill have just as good of luck

where did you find a green ac belt? are you using the stretch belt or with the tensioner? (i just wanted to match the reg belt not really a huge deal)

ordered new driers for mine (for cab and chiller) and a new orifice tube also...should have prob done so before running with new compressor but o wel
Amazon for the belt, it’s a Gates Fleet Runner. I have the tensioner.

And yes I guess they say to use a new accumulator/ dryer if you replace the compressor according to alldata.
 

randeez

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Amazon for the belt, it’s a Gates Fleet Runner. I have the tensioner.

And yes I guess they say to use a new accumulator/ dryer if you replace the compressor according to alldata.
ahh thats why, im using stretch belts and couldnt find a greeny to match.

i think im more worried about the drier for the chiller - its been off a few months in garage, but prob still soaked up plenty of moisture into the desiccant
 
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Rocket Man

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ahh thats why, im using stretch belts and couldnt find a greeny to match.

i think im more worried about the drier for the chiller - its been off a few months in garage, but prob still soaked up plenty of moisture into the desiccant
Yeah if it’s been exposed to the atmosphere then it was done long ago. It doesn’t take long when it has unlimited moisture to suck on. The new one I bought had a vacuum on it. I loosened one of the seals they had on it where it connects and it went “whoosh” so I sealed it back up. It’s gonna be a few days before I install it.
 

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Yeah if it’s been exposed to the atmosphere then it was done long ago. It doesn’t take long when it has unlimited moisture to suck on. The new one I bought had a vacuum on it. I loosened one of the seals they had on it where it connects and it went “whoosh” so I sealed it back up. It’s gonna be a few days before I install it.
yea i need to try and get a part no off it or something, its just a universal one with 3/8 oring fitting in and out, but where its mounted ive got to replace it with one pretty much the exact same size +/- 1/2"
 
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Rocket Man

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I figured I’d get everything flushed except the line I ordered. Everything was going good until I got to the rear. I looked underneath the rear floor where the lines connect to, I’m assuming, the rear evaporator. I figured I’d just flush everything in place, no sense to disconnect the lines and flush the evaporator separate. So I loaded 3/4 a quart of cleaner, hooked up a hose to the return line to collect in a bucket, and hit the button on the tool. I was ready this time but I was expecting it to come out the return line. It did not. It shot back out of the line I was putting it into. Something is completely blocked. Not sure if it’s the evaporator or the lines but I’ll bet which one it is. I pressure washed that area and removed the nuts holding the lines on. The big one came off. The small one not so much. I shot it with WD and waited a bit, put some vise grips on the block and tried twisting and pulling. Nothing. It’s hot out there so I am on break again. Ill pull the interior panel tomorrow morning and get that line off. Then I’ll figure out wtf is going on. I do have a new evaporator on order if needed. But that line needs to come off. Maybe if it soaks overnight. It’s not an easy spot to get to as far as prying and such.
 

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