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

I got the rear lines yesterday and installed everything this morning. I highly recommend that rear line kit from Auto Cooling Solutions. Fit was perfect and they went right back where the hard lines were only they were easy to route because they’re flexible. The mounting clips snapped closed on them perfectly. The smaller line had about 6” extra so I just put a small loopy thing by the frame along the side.

Everything fit perfectly, and I took it to my buddy’s shop. After 2.7 lbs of Freon was put in, it’s blowing nice and cold front and rear.

And of course there was this nice bagged C10 in there for some touch up.

Rocket Man said:

The new expansion valve didn’t come with instructions nor was alldata much use. There were 2 o-rings in there so I removed the old one to see where they go. Alldata said to reuse the packing around the thermal thing so I removed it from the old one and discovered a lot of rust around that thing. It may have been faulty. Not sure why it was so rusty.

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I'm so glad I didn't need to go through all that rear ac crap you had to go through. I learned a lot though. Great job Mark.

Rocket Man said:

I got the rear lines yesterday and installed everything this morning. I highly recommend that rear line kit from Auto Cooling Solutions. Fit was perfect and they went right back where the hard lines were only they were easy to route because they’re flexible. The mounting clips snapped closed on them perfectly. The smaller line had about 6” extra so I just put a small loopy thing by the frame along the side.

Everything fit perfectly, and I took it to my buddy’s shop. After 2.7 lbs of Freon was put in, it’s blowing nice and cold front and rear.

And of course there was this nice bagged C10 in there for some touch up.

Click to expand...

Awesome job knocking down the numerous issues and obstacles and getting this done.

Rocket Man said:

I got the rear lines yesterday and installed everything this morning. I highly recommend that rear line kit from Auto Cooling Solutions. Fit was perfect and they went right back where the hard lines were only they were easy to route because they’re flexible. The mounting clips snapped closed on them perfectly. The smaller line had about 6” extra so I just put a small loopy thing by the frame along the side.

Everything fit perfectly, and I took it to my buddy’s shop. After 2.7 lbs of Freon was put in, it’s blowing nice and cold front and rear.

And of course there was this nice bagged C10 in there for some touch up.

Click to expand...

What the hell is all that shÌt in your fender there? Mud?

Rocket Man said:

I got the rear lines yesterday and installed everything this morning. I highly recommend that rear line kit from Auto Cooling Solutions. Fit was perfect and they went right back where the hard lines were only they were easy to route because they’re flexible. The mounting clips snapped closed on them perfectly. The smaller line had about 6” extra so I just put a small loopy thing by the frame along the side.

Everything fit perfectly, and I took it to my buddy’s shop. After 2.7 lbs of Freon was put in, it’s blowing nice and cold front and rear.

And of course there was this nice bagged C10 in there for some touch up.

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You probably did already, but don't forget to snap that clip back in.

89Suburban said:

What the hell is all that shÌt in your fender there? Mud?

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Yep. From having cut up fender liners. Pressure washed all 4 fender wells today, tidied up some wires, snapped that clip in and installed the new liners. Also sprayed that foam crap into the evaporator but didn’t think about the fact that I was supposed to run the AC afterwards and it would turn to liquid and drip out the hole. Well it was 55 degrees outside and the AC didn’t really come on. So I did everything else and came back later and took it for a drive. My thermometer said about 42*. And dripping happened.

Then since I had assembled the rear side panel yesterday, today I noticed the rear AC not working. I hooked up the Tech 2 and it said the temp at the outlets was 90-100. The fan wasn’t running. So I tear the rear apart again and the fan comes on and it’s blowing cold air, wtf. I touched the blower resistor and fan goes off. The wiring connector was getting hot and it was intermittent. Wiggle it anc the fan goes on and off. I removed it and it smells burnt. I see it has a loose pin where it connects to the board, so I ordered a new one. 2 days from Amazon for a genuine GM one.

And now every hose under the hood except the upper and lower radiator hoses are braided or covered in braided loom except this one small one. See it?

89Suburban said:

What the hell is all that shÌt in your fender there? Mud?

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Hey dude, you can say shit on here. I mean, it's not like saying ******* or anything. We're all grown ups...













For those curious, that's hard. On. That's blurred out...

I said fock it and opened that thing up and found the ground pin had a broken connection and was loose so I soldered that sucker. It was working fine hanging there. Success! Put it back in the case and plugged it in again. Nothing. Pulled the connector halfway back out and it came on. Connector was melted around the ground wire terminal and it was collapsed, but I couldn’t pull that one out. The other 2 I could release and remove but not that one. It’s melted to the plug. So I cut a hole in the side of the plug with my Dremel and stuck a tiny tool in there and spread that spring terminal inside the connector and it’s working great. It’s not getting hot but I’ll leave the rear cover off and monitor it. I looked and can’t find that connector online, maybe because it’s an 02. All the ones I see are 5 or 7 pin, for the front.