A/C Compressor

rflow50 · June 19, 2006

Hello, I am new to this forum. This is the problem with my 2000 GMC YUKON. The Truck has the 5.3 engine with 70,000 miles. A month ago the A/C Compressor started making a rattle noise every time the compressor will kick in at certain RPM's but the A/C was still cooling very strong. I took the Truck to different Mechanic Shops, all of them told me that the compressor was going bad. I decided to order a remanufactured compressor from Ebay. I took the truck to a mechanic shop to get it installed along with an orifice tube. A week after the installation it started making the same noise again. This time the rear A/C stop cooling, I took the Truck back to the mechanic, he check the truck and added a 2oz of compressed oil and 2oz of freon. The noise was still there, and hour later the freon was coming out from the compressor area, the mechanic over charged the compressor.

I decided to remove the A/C compressor myself to avoid charges and I send it back for guarantee. The guy send me another compressor but told me that it was going to be the last one because his technician told him that the mechanic that did my service did not flush the system correctly and it plugged the lines making the Compressor to go bad. The guy also advised me to change the accumulator and expansion valve.

I took the truck to a different mechanic for the installation of the compressor. I also went to look for an accumulator. Man I was having so much trouble finding one because none of the local auto part will give me the correct one. Finally one place sold me one but i needed to bend the A/C hose just a little bit to make it fit. After the installation the mechanic told me that the compressor was still making the same noise and told me that i needed to get the rear Expansion Vale because the rear A/C was not cooling. He also told me that the orifice tube was full of metal shavings and he replaced with a new one. I decided to go to a GM dealership and with the VIN# they told me that i needed to change to A/C hose#15065473 to match the accumulator#1132781 because GM came with this new setup, because the other A/C hoses 15065471 and 15065472 might be starving the compressor for oil making the compressors to make that noise.

This morning I ordered the A/C hose along with the rear expansion valve, hoping to solve this problem. Three A/C compressors and they all make the same noise. Anybody has experience this problem before. Any advise is greatly appreciated. Rick

ChevyTech007 · June 20, 2006

Here is one bulletin:

Subject: Info - J 44551 A/C Suction Screen Kit Repair Recommendations and Procedures After Catastrophic Compressor Failures #01-01-39-003A - (07/14/2003)

Models: 1997-2004 Passenger Cars and Light Duty Trucks

2003-2004 HUMMER H2

with Delphi HD6, HU6 and HT6 Compressors

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This bulletin is being revised to update model years and add the HUMMER H2. Please discard Corporate Bulletin Number 01-01-39-003 (Section 01 - HVAC).

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GM Service Operations and Delphi Thermal Systems have worked with GM dealers over the past three years to develop the tools and procedures to increase your success rate on repairing vehicle A/C systems that experience catastrophic compressor failures.

After a catastrophic compressor failure, it is extremely important to eliminate and/or contain the debris that causes repeat repairs. The debris generated from a catastrophic compressor failure is discharged into the compressor suction line, the discharge line, the condenser and the liquid line. The use of the J 44551 Suction Screen Kit DOES NOT replace the need for liquid line filters as described in the vehicle specific Service Manual. Liquid line filters should be used whenever possible (after a catastrophic compressor failure) to protect the expansion device (orifice tube or TXV) from debris.

Analysis of failed replacement compressors show the debris discharged into the INLET side of the compressor (suction line) is often pulled into the replacement compressor. It is important to keep this debris out of the new compressor to avoid repeat compressor failure. The J 44551 Suction Screen Kit is designed to help protect the NEW (replacement) compressor from ingesting debris that was sent into the SUCTION side of the system during a compressor failure.

The J 44551 kit supplies your dealership with the right tools and supplies to cover the Delphi HD6, HU6 and HT6 compressors for most GM applications. Delphi V5 and V7 compressors already have this screen installed in the suction port of the compressor and do not need an additional screen installed.

Service Procedure

Tools Required

J 44551 Suction Screen Kit

The J 44551 Suction Screen Kit contains three different screen sizes. It is important to select the correct size screen that will press fit into the suction port of the compressor hose assembly. The screen should not be installed loose inside the hose assembly.

Installation Procedure

Evacuate the air conditioning system completely using the applicable recovery equipment.

Remove the bolt that attaches the manifold of the muffler assembly hose to the air conditioning compressor.

Use the Suction Port Sizing Tool (1) in order to determine the appropriate size filter screen.

Install the proper Installation Mandrel (1) on the threaded portion of the Installation Tool.

Using the Installation Tool, place the manifold into the fixture of the tool.

5.1. Lubricate the applicable filter screen with refrigerant lubricant.

5.2. Ensure that you are on the suction side of the air conditioning manifold.

5.3. Place the filter screen straight into the bore before proceeding.

5.4. Using a 9/16 in wrench, turn the bolt of the Installation Tool (3) clockwise, pressing the filter screen (2) into the bore.

The filter screen must be flush with or slightly below the bore.

Reinstall the manifold (1) on the rear of the air conditioning compressor. Make sure to tighten to the correct specifications.

Important: Be sure to clean the appropriate surface before applying the Notification Label.

Included in the kit is a bright yellow Notification Label with the following message: ATTENTION! Suction Line Screen Installed. It is very important that you apply this label to the manifold, the suction line, or some other appropriate, highly visible location.

Removal Procedure

Using the appropriate Removal Tool (1), place the Removal Tool (1) into the bore of the filter screen.

Turn the Removal Tool one turn clockwise, or until tight.

Turn the nut clockwise to remove the filter screen using the appropriate size wrench.

• 11/16 in wrench for size A filter screen

• 3/4 in wrench for size B filter screen

• 7/8 in wrench for size C filter screen

ChevyTech007 · June 20, 2006

Here is another. Sounds like you had (have) a lot of metal in the system. Rear expansion valve clean orifice and a good flush are in order.

Subject: Noise in Engine Compartment with Air Conditioning (A/C) On, A/C System Inoperative (Install Redesigned Rear A/C Suction Hose, Replace Compressor) #01-01-39-002B - (12/03/2001)

Models: 2000-2001 Chevrolet and GMC C/K Utility Models

Built Prior to October 10, 2000

With Auxiliary Rear A/C (RPO C69)

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This bulletin is being revised to add additional procedure information. Please discard Corporate Bulletin Number 01-01-39-002A (Section 01 -- HVAC).

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Condition

Some customers may comment on excessive noise from the engine compartment with the A/C on. Some customers also may comment that the A/C system is inoperative.

Cause

Under certain driving conditions, the A/C compressor may be starved of oil.

Correction

Important: Do NOT use Rear Auxiliary A/C Line P/Ns 15065471 and 15065472.

Important:

Flushing the A/C System After Catastrophic Compressor Failure

• A/C system flushing should NOT be routinely performed when a system failure is encountered. System flushing takes a considerable amount of time to perform and is NOT necessary on most system failures. System flushing requires prior authorization by the GM Area Service Manager (in Canada, the District Service Manager) and should be performed only when any one of the following conditions is found.

• Desiccant bag failure

• Gross overcharge of PAG oil

• Refrigerant contamination

• Contaminated PAG oil

• Catastrophic compressor failure causing oil contamination

• A/C system flushing will remove some of the metal particles during a flush, but flushing is not completely effective in removing all metallic debris. System flushing should not be considered if removal of metallic debris is the only objective. GM Service Operations continues to recommend the use of LIQUID LINE FILTERS to control this type of system contamination and avoid repeat failures.

• A warm engine compartment or higher ambient temperatures speed the refrigerant recovery time during the A/C flush procedure. Whenever possible, warm the engine prior to system flushing.

Front/Rear (Dual Circuit) A/C Systems

Important: Each circuit of a front/rear A/C system must be flushed separately. Flow to one circuit must be blocked with the use of a blocked orifice tube or blocked TXV. The front circuit should always be flushed first.

Front Circuit

Recover the system refrigerant.

Remove the expansion device (TXV or orifice tube) from the front circuit.

Re-connect the A/C lines with the orifice tube removed or install the appropriate non-blocked (open) TXV Adapter from kit J 45268.

Important: A blocked orifice tube is not supplied with the J 45268 Adapter kit. A blocked orifice can be made using the following steps:

Cut the orifice tube frame and screen.

Remove enough of the frame and screen to access the end of the orifice tube.

Seal the tube by pinching off the end of the orifice tube.

Remove the expansion device (TXV or orifice tube) from the rear circuit and install a plugged expansion device (TXV or orifice tube) into the rear circuit.

Remove the A/C compressor. Refer to the service procedure below.

Install the appropriate A/C compressor hose assembly flush adapter(s) from kit J 45268.

Configure the flush adapter and hose for either a forward flush or reverse flush. Refer to the Flushing Configuration below.

Perform the flush of the front system by following the instructions supplied with the J 43600 ACR 2000.

Replace the plugged expansion device (TXV or orifice tube) in the rear circuit with an open expansion device (TXV or orifice tube).

Replace the open expansion device (TXV or orifice tube) in the front circuit with a plugged expansion device (TXV or orifice tube) .

Flush the rear system by following the instructions supplied with the J 43600 ACR 2000.

Flushing Configuration - Forward Flush

Forward flushing (the same flow as normal system operation) is recommended for contaminated refrigerant or PAG oil.

Important:

• Install a new filter inside the J 45268-1 for every flush. Service the filter with P/N 5651802 (in Canada, use P/N 729832). Remove and discard the check valve filter from the filter.

• Always close the valve on the J 43600 ACR 2000 external refrigerant tank before starting the flush process.

Connect the flush filter adapter J 45268-1 to the suction port of the A/C compressor hose assembly flush adapter.

Connect the blue hose from the J 43600 ACR 2000 to the J 45268-1 flush filter adapter.

Connect the red hose from the J 43600 ACR 2000 to the discharge port of the A/C compressor hose assembly flush adapter.

Follow the instructions supplied with the J 43600 ACR 2000 and flush the A/C system.

Flushing Configuration - Reverse Flush

Reverse flushing (the opposite flow of normal operation) is recommended for desiccant bag failure. Always replace the accumulator after the reverse flushing procedure is complete.

Important:

• Install a new filter inside the J 45268-1 for every flush. Service the filter with P/N 5651802 (in Canada, use P/N 729832). Remove and discard the check valve from the filter.

• Always close the valve on the J 43600 external refrigerant tank before starting the flush process.

Connect the J 45268-1 flush filter adapter to the discharge port of the A/C compressor hose assembly flush adapter.

Connect the blue hose from the J 45268-1 flush filter adapter.

Connect the red hose to the suction port of the A/C compressor hose assembly flush adapter.

Follow the instructions supplied with the J 43600 ACR 2000 and flush the A/C system.

Important: Refer to Corporate Service Bulletin Number 01-01-38-006A (SI 2000 Document ID #803991) for additional flushing information.

Service Procedure

Follow the service procedure below to eliminate additional compressor failures.

Open the hood.

Install fender covers.

Disconnect the negative battery cable from the battery.

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).

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

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.

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).

Install the new suction hose, P/N 15065473, to the compressor (2) and to the accumulator. Refer to the Suction Hose Replacement LR4, LM7, LQ4, L18 w/Denso procedure in the Service Manual (SI 2000 Document ID #628200).

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

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.

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

Remove the burrs from the evaporator tube (2).

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

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

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

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

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

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 N·m (11 lb ft).

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

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

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

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

Tighten

Tighten the nuts to 15 N·m (11 lb ft).

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

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.

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

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).

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

Tighten

Tighten the nut to 16 N·m (12 lb ft).

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

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).

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).

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

Remove the upper radiator close out panel.

Remove both headlamp assemblies.

Remove the grille.

Remove both turn signal lamp assemblies.

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

Remove the condenser.

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 N·m (12 lb ft).

• Tighten the condenser mounting bolts to 2.4 N·m (21 lb in).

Install the six bolts retaining the radiator support brace.

Tighten

Tighten the radiator brace bolts to 9 N·m (80 lb in).

Install the turn signal lamps.

Install the grille.

Tighten

Tighten the grille screw to 9 N·m (75 lb in).

Install the head lamp assemblies.

Install the upper radiator close out panel.

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

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

Parts Information

Part Number

Description

01132781

Accumulator Asm. - A/C

03096068

Orifice Asm. - A/C

12345923

(In Canada use 10953486)

Oil-PAG A/C Compressor

12346303

(In Canada use 10953458)

Dye - A/C System

12356150

(In Canada use 12345922

Refrigerant - A/C (R134a)

15095996

Hose Asm.- Aux. A/C Suction.

15065473

Hose Asm.- A/C Accum

15081861

Compressor Asm.- A/C

52474433

Filter Asm., A/C Refrig (inline w/o orifice)

52475996

Condenser Asm. - A/C

52491670

Valve Kit, Aux A/C Evap Therm Expn

Parts are currently available from GMSPO.

lebolewis · June 20, 2006

Hello, I am new to this forum. This is the problem with my 2000 GMC YUKON. The Truck has the 5.3 engine with 70,000 miles. A month ago the A/C Compressor started making a rattle noise every time the compressor will kick in at certain RPM's but the A/C was still cooling very strong. I took the Truck to different Mechanic Shops, all of them told me that the compressor was going bad. I decided to order a remanufactured compressor from Ebay. I took the truck to a mechanic shop to get it installed along with an orifice tube. A week after the installation it started making the same noise again. This time the rear A/C stop cooling, I took the Truck back to the mechanic, he check the truck and added a 2oz of compressed oil and 2oz of freon. The noise was still there, and hour later the freon was coming out from the compressor area, the mechanic over charged the compressor.

I decided to remove the A/C compressor myself to avoid charges and I send it back for guarantee. The guy send me another compressor but told me that it was going to be the last one because his technician told him that the mechanic that did my service did not flush the system correctly and it plugged the lines making the Compressor to go bad. The guy also advised me to change the accumulator and expansion valve.

I took the truck to a different mechanic for the installation of the compressor. I also went to look for an accumulator. Man I was having so much trouble finding one because none of the local auto part will give me the correct one. Finally one place sold me one but i needed to bend the A/C hose just a little bit to make it fit. After the installation the mechanic told me that the compressor was still making the same noise and told me that i needed to get the rear Expansion Vale because the rear A/C was not cooling. He also told me that the orifice tube was full of metal shavings and he replaced with a new one. I decided to go to a GM dealership and with the VIN# they told me that i needed to change to A/C hose#15065473 to match the accumulator#1132781 because GM came with this new setup, because the other A/C hoses 15065471 and 15065472 might be starving the compressor for oil making the compressors to make that noise.

This morning I ordered the A/C hose along with the rear expansion valve, hoping to solve this problem. Three A/C compressors and they all make the same noise. Anybody has experience this problem before. Any advise is greatly appreciated. Rick

<{POST_SNAPBACK}>

I just purchased a 1994 GMC 2500 series Suburban that has a replacement compressor in it. The former owners said that they replaced the original one with a new GM compressor about 3 tears ago and after a year (after the warranty expired), it started making a "chattering" noise when it was on. They took it back and was told the noise was "normal" for some replacement compressors. It still makes that noise, and has been making it for 2 years now, but otherwise, it works fine.

rflow50 · June 20, 2006

Thanks for the advise. I don't think that the noise is normal, I am going to change the hose and rear expansion valve and see what happens. Those bulletins are very helpful. thanks again Rick

rflow50 · June 30, 2006

Well Yesterday, i was installing the new A/C hose design that goes to the accumulator and the accumulator, and what a surprise when i was about to finish the installation i notice that the the hose that goes to the rear A/C was not going to fit. I went to the GM Dealer and the guy told me that it was also required to change it along with the other two things. The price at the Dealership for that hose was $400.00 but i was able to get at a different part store for $185.00. I did not have the time to installation myself since you have to remove fender covers and do more stuff. I took it to a mechanic and he is going to charge me $220.00 labor and he also is going to do the flush on the system again.

I hope this time the A/C compressor doesn't fail, like the other two. The guy at the dealership was telling me that what GM is doing is using the same exact parts that the 2003-2005 Yukon are equipped with. Don't understand the reason, because if you want to change the A/C Compressor on the 2000-2001 model you have two basically replace the accumulator, two A/C hoses to make things fit and that's kind of pricey.

So far i was doing calculations and I spend $1200.00 already(parts and labor) since my original compressor went bad and i hope this time there no more parts require.

rflow50 · June 30, 2006

I just came back from the mechanic and the rattle sound is still on the compressor. It only does the noise when i take off from a stop and hit 30mph, then the rattle sounds stops. The mechanic told me that is liquid going into the compressor but how can you fix that. I already change everything is required as per the bulletin.

bajakid2 · July 1, 2006

hey, my truck does the same thing it gets really annoying but my a/c works perfect...heres a link to a video i took does it sound like this?

Thanks-Travis

GM-Tech · July 1, 2006

I just came back from the mechanic and the rattle sound is still on the compressor. It only does the noise when i take off from a stop and hit 30mph, then the rattle sounds stops. The mechanic told me that is liquid going into the compressor but how can you fix that. I already change everything is required as per the bulletin.

<{POST_SNAPBACK}>

Sounds to me like maybe the a/c is not your problem. Perhaps the tensioner, etc. I ASSUME there's no noise if the a/c is off?

rflow50 · July 2, 2006

I just came back from the mechanic and the rattle sound is still on the compressor. It only does the noise when i take off from a stop and hit 30mph, then the rattle sounds stops. The mechanic told me that is liquid going into the compressor but how can you fix that. I already change everything is required as per the bulletin.

<{POST_SNAPBACK}>

Sounds to me like maybe the a/c is not your problem. Perhaps the tensioner, etc. I ASSUME there's no noise if the a/c is off?

<{POST_SNAPBACK}>

yes when the A/C is off there is no noise. Today i notice that when i take off at a lower speed or my RPM's dont go over 1300 there is no noise. I guess it only does it when my RPM go over 2000 at the take off or when i rev the truck at idle. It's weird because at higher speeds it doesn't do it. Can it be that not enough oil is circulating through the compressor.

rflow50 · July 2, 2006

I just took a video of the truck but i don't know how to post the video, can someone post it for me. thanks rick

bajakid2 · July 2, 2006

Hey i could post it for you if you would like...

-Travis

rflow50 · July 2, 2006

Hey i could post it for you if you would like...
-Travis

<{POST_SNAPBACK}>

Thanks, what is your email so i can send the video to you. Rick

ChevyTech007 · July 3, 2006

yes when the A/C is off there is no noise. Today i notice that when i take off at a lower speed or my RPM's dont go over 1300 there is no noise. I guess it only does it when my RPM go over 2000 at the take off or when i rev the truck at idle. It's weird because at higher speeds it doesn't do it.

This sounds familiar. I have seen it on a couple of trucks. You need to move your fan back and forth as fast as you can. If it gets real easy to turn after you do that, you need a fan clutch. It causes very high high side pressures and the pop off valve goes off on acceleration. Check this out and post back.

rflow50 · July 3, 2006

yes when the A/C is off there is no noise. Today i notice that when i take off at a lower speed or my RPM's dont go over 1300 there is no noise. I guess it only does it when my RPM go over 2000 at the take off or when i rev the truck at idle. It's weird because at higher speeds it doesn't do it.

This sounds familiar. I have seen it on a couple of trucks. You need to move your fan back and forth as fast as you can. If it gets real easy to turn after you do that, you need a fan clutch. It causes very high high side pressures and the pop off valve goes off on acceleration. Check this out and post back.

<{POST_SNAPBACK}>

I just finish doing what you told me and is not real easy to turn, so i guess is not the fan clutch. thanks for the advice.