Service Procedure

Follow the service procedure below to eliminate additional compressor failures.

1. Open the hood.

2. Install fender covers.

3. Disconnect the negative battery cable from the battery.

4. Recover the refrigerant. Refer to the Refrigerant Recovery and Recharging procedure in the Service Manual (SI 2000 Document ID # 291142).





Important:
^ Add 60 ml (2 oz.) of PAG oil, P/N 12345923 (in Canada, use P/N 10953486), plus the equal amount of oil drained from the accumulator.

^ Do not install the old suction hoses from the compressor and the rear A/C line to the new accumulator (3).

5. Replace the accumulator (3) with P/N 1132781. Refer to the Accumulator Replacement procedure in the Service Manual (SI 2000 Document ID # 542037).





6. Replace the expansion (orifice) tube (1) with P/N 03096068. Refer to the Expansion (Orifice) Tube Replacement procedure in the Service Manual (SI 2000 Document ID # 536021).

Important:
^ Do not install the old suction hose to the new compressor.

^ Do not reinstall the wheelhouse panel to the wheelhouse at this time.

^ Drain and measure as much of the oil as possible from the removed compressor.

^ Drain the oil from both the suction and discharge ports of the removed A/C compressor into a clean container.

^ Measure and record the amount of oil drained from the removed A/C compressor. This measurement will be used during installation of the replacement A/C compressor.

^ If more than 60 ml (2 oz.) of PAG oil was drained from the compressor, add the equal amount of PAG oil that was drained from the old compressor.

^ If less than 60 ml (2 oz.) of PAG oil was drained from the compressor, add 60 ml (2 oz.) of PAG oil to the new compressor.





7. Replace the A/C compressor (2) with P/N 15081861. Refer to the Compressor Replacement LR4, LM7, LQ4, L18 w/Denso procedure in the Service Manual (SI 2000 Document ID # 448700).





8. Install the new suction hose, P/N 15065473, to the compressor (2) and to the accumulator. Refer to the Suction Hose Replacement LR4, LM7, L04, L18 w/Denso procedure in the Service Manual (SI 2000 Document ID # 628200).

9. Remove the retainer from the evaporator tube (2) to the air cleaner support bracket.

10. Measure 152 mm (6 in) in front of the Y in the evaporator tube (2) and mark.

Important:
^ Denso DOES NOT RECOMMEND the use of SUCTION SCREEN FILTERS with Denso compressors.

^ Do not allow metal burrs to enter the evaporator tube (2) during cutting or when removing the burrs.

^ When you section the A/C lines, ensure that the correct minimum length remains in the straight part of the line on both sides of the filter.

11. Using a tubing cutter, cut the marked section of the evaporator tube (2).

12. Remove the burrs from the evaporator tube (2).





13. Remove the nuts (4), the ferrules (3), and the 0-rings (2) from the A/C refrigerant filter (1).

Important:
Do not install the 0-rings (2) in this step.

14. Push the nuts (4) and ferrules (3) over each of the evaporator tube halves.

15. Install the ferrules (3) with the small end toward the nut (4).

16. Install the A/C refrigerant filter (3), P/N 52474433, to the evaporator tube (2) with the flow arrow pointing towards the evaporator.

17. While holding the evaporator tube in the A/C refrigerant filter (1), tighten the nuts (4) to the A/C refrigerant filter (1).

Tighten

Tighten the nuts to 15 Nm (11 lb ft).

18. Remove the nuts (4) from the A/C refrigerant filter (1).

19. Coat the 0-rings (2) with 525 viscosity Mineral oil, P/N 5416939 (in Canada, use P/N 10953496).

20. Install the 0-rings (2) to the evaporator tube halves.

21. Install the nuts (4) to the A/C refrigerant filter (1).

Tighten

Tighten the nuts to 15 Nm (11 lb ft).

22. Install the retainer to the evaporator tube to air cleaner support bracket.

23. Raise the vehicle and locate the rear A/C suction line on the right side pinch weld.

Important:
^ Measure 152 mm (6 in) rear of first rear A/C line retaining clip and mark the suction line.

^ Do not allow metal burrs to enter the rear A/C suction line.

^ When you section the A/C lines, ensure that the correct minimum length remains in the straight section of the line on both sides of the splice.

24. Using a tubing cutter, cut the marked section of the rear A/C suction line and discard the front section of the line.

25. Splice in the new front section of rear A/C suction hose, P/N 15095996, using J 41425 A/C Line Repair Kit and splice J 41425-750. Refer to the Heater and A/C Pipe Repair - Auxiliary procedure in the Service Manual (SI 2000 Document ID # 594055).

26. Connect the rear A/C suction line to the Y in the suction line attached to the compressor.

Tighten

Tighten the nut to 16 Nm (12 lb ft).

27. Install the wheelhouse panel to the wheelhouse. Refer to the Wheelhouse Panel Replacement procedure in the Service Manual (SI 2000 Document ID # 449783).





28. Replace the rear thermo expansion valve with P/N 52491670. Refer to the Thermal Expansion Valve Replacement - Auxiliary procedure in the Service Manual (SI 2000 Document ID # 594045).

29. Add A/C system Fluorescent Tracer Dye to the A/C system, P/N 12346303 (in Canada, use P/N 10953458). Refer to the Leak Testing procedure in the Service Manual (SI 2000 Document ID # 4486920).

30. Add the A/C system dye notification label to the upper radiator support.

Important:
^ Vehicles that have had multiple compressor failures due to oil starvation should replace the condenser.

^ Do not replace the condenser if the compressor has not been replaced prior to this repair.

Condenser Replacement

1. Remove the upper radiator close out panel.

2. Remove both headlamp assemblies.

3. Remove the grille.

4. Remove both turn signal lamp assemblies.

5. Remove the six bolts retaining the radiator support brace and position the brace so that the condenser can be removed.

6. Remove the condenser.

7. Install a new condenser, P/N 52475996, and add 30 ml (1 oz) of PAG oil, P/N 12345923 (in Canada, use P/N 10953486).

Tighten

^ Tighten the suction and discharge line to 16 Nm (12 lb ft).

^ Tighten the condenser mounting bolts to 2.4 Nm (21 lb in).

8. Install the six bolts retaining the radiator support brace.

Tighten

Tighten the radiator brace bolts to 9 Nm (80 lb in).

9. Install the turn signal lamps.

10. Install the grille.

Tighten

Tighten the grille screw to 9 Nm (75 lb in).

11. Install the head lamp assemblies.

12. Install the upper radiator close out panel.

13. Recharge the A/C system. Refer to the Refrigerant Recovery and Recharging procedure in the Service Manual (SI 2000 Document ID # 291142).

14. Perform the System Performance Test (Suburban/Yukon XL) procedure in the Service Manual (SI 2000 Document ID # 631165).