Table of Contents. First Aid for Refrigerant Exposure 35. First Aid for Skin Exposure / First Aid for Eye. Chapter 3:

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2 Table of Contents Chapter 1: Introduction to Automotive Heating, Air Conditioning, and Ventilation 11 Heating, Ventilating, and Air Conditioning (HVAC) Systems 12 Why Is It Called HVAC? Major Heating, Ventilation, and Air Conditioning System Components 12 Refrigeration System Parts and Operation / Heating System Parts and Operation / Air Delivery System Parts and Operation HVAC System Controls 19 Mechanical Devices HVAC System Operation 20 Air Conditioning / Ventilating / Heating / Defrost HVAC System History 21 Heaters / Ventilation / Air Conditioning The Air Conditioner and the Ozone Layer 23 Chapter 2: Shop Safety and Environmental Protection 27 Causes of Accidents 28 Personal Safety Equipment 28 Proper Clothing and Protective Equipment / Eye Protection / Foot and Hand Protection Kinds of Accidents 29 Maintaining a Safe Workplace / Performing Work Procedures Properly Refrigerant Safety Precautions 34 Vapor and Liquid Refrigerants / Rules for Handling Refrigerants First Aid for Refrigerant Exposure 35 First Aid for Skin Exposure / First Aid for Eye Exposure / First Aid for Breathing Difficulty Preventing Environmental Damage 35 Prevent Solid Waste Contamination / Prevent Liquid Waste Contamination / Prevent Gaseous Waste Contamination / The Environmental Protection Agency Chapter 3: HVAC Tools, Equipment, and Service Information 39 Diagnostic and Test Equipment 40 Gauge Manifolds / Temperature Gauges / Leak Detectors / Refrigerant Identifiers / Electrical Test Equipment / Belt Tension Gauges / Vacuum Pumps/ Gauges HVAC System Service Tools 47 Compressor Service Tools / Compressor Clutch Service Tools / Hose Tools / Orifice Tube Tools / Oil Injectors Refrigerant Service Equipment 51 Recovery/Recycling Equipment/Flushing Equipment/ Evacuation Pumps / Recharging Equipment / Air Purging Equipment Engine Cooling System Test Equipment 54 Pressure and Leak Testers / Antifreeze Testers / Combustion Leak Testers Vehicle Protection 56 Service Information 57 Factory Manual / General Manual / Specialized Manual / Technical Service Bulletins/Telephone Hotlines/ Internet Resources

3 Table of Contents 7 Chapter 4: HVAC Electrical and Electronic Fundamentals.. 63 Electrical Basics 64 Conductors and Insulators / Electrical Measurements /' Direct and Alternating Current / Types Circuits / Circuit Defects Electromagnetism 67 of Electrical Vehicle Wiring and Electrical Components 68 Wiring / Wiring Schematics / Circuit Protection Devices / Switches / Solenoids, Relays, and Magnetic Clutches / Motors / Resistors / Capacitors Basic Electrical Diagnosis 75 Electrical Device Not Working / Electrical Device on at All Times Vehicle Computers 75 Semiconductor Materials / Computer Circuits / Control Loops / Main Computer Sections / Computer Diagnostic Outputs Chapter 5: Principles of Refrigeration 81 The Purpose of Refrigeration 82 Basic Principles of Refrigeration 82 Heat and Cold / Heat Transfer / Change of State / Sensible and Latent Heat/The Pressure-Temperature Relationship Refrigeration Components 85 The Two Main Types of Refrigeration Systems / Evaporator / Accumulator / Compressor / Muffler / Condenser / Receiver-drier / Filter / Sight Glass / Flow Restrictor / Connecting Lines / Service Fittings / Seals and Gaskets / Which Parts Are Used on Which Systems? / Refrigerants The Refrigeration Cycle 91 Cooling Phase Evaporator / Pressure Increase Phase Compressor / Heat Transfer Phase Condenser / Pressure Decrease Phase Flow Restrictor / Factors That Affect System Performance Chapter 6: Refrigerants, Refrigerant Oils, and Related Chemicals 97 Refrigerant Purposes 98 Refrigerants and Governmental Regulation 98 Montreal Protocol / Clean Air Act Types of Refrigerants 99 R-134a / R-12 (Freon) / R-134a versus R-12 Refrigerant Classification 101 Blended Refrigerants (Azeotropic and Zeotropic Blends) / Drop-in Refrigerants / New Refigerants Replacement Refrigerants 102 Choosing a Replacement Refrigerant / SNAP Program Refrigerant Oils 104 Types of Refrigerant Oil Other Refrigeration System Chemicals 105 Desiccants / Flushing Compounds / Leak Detector Dyes / Evaporator Surface Cleaners / Refrigeration System Sealers Chapter 7: Hoses, Lines, Fittings, and Seals 109 Hoses and Lines 110 Hoses / Metal Lines / Combination Hose and Line Assemblies / Hose and Line Attachments / Hose and Line Size Specifications Refrigeration System Fittings 112 Compression Fittings / Crimp Fittings / Spring Lock Couplings / Screw Type Hose Clamps / Service Fittings Making Hoses, Lines, and Fittings 116 Refrigeration Sealing Devices 116 Compressor Shaft Seals / O-ring Seals / Sealing Washers / Gaskets Chapter 8: Compressors, Clutches, and Drives 121 Compressor Purposes 122 Basic Compressor Parts 122 Types of Compressors 122 Piston Compressors / Rotary Vane Compressors / Scroll Compressors Compressor Capacity Control Valves 130 Compressor Drives and Clutches 130 Compressor Drive / Compressor Clutches / Compressor Clutch Control Systems / Constantly Engaged Compressor Clutch Compressor Makes and Models 135 Bosch / Calsonic / Chrysler / Frigidaire/Harrison/ Delco Air/Delphi / Ford / Hitachi / Keihin / Matsushita/Panasonic / Mitsubishi / Nihon/Nihon Radiator / Nippondenso / Sanden/Sankyo / Seiko- Seki / Seltec / Tecumseh/York / Unicla / Zexel/Diesel Kiki / Older Compressors Chapter 9: Evaporators, Condensers, Accumulators, and Receiver-Driers 143 Evaporators 144 Evaporator Design and Construction / Types of Evaporators / Parts Attached to the Evaporator Condensers 146 Condenser Design Accumulators 148 Accumulator Operation Receiver-Driers 148 Desiccants Pressure Relief Devices 150

4 8 Auto Heating & Air Conditioning Chapter 10: Control Valves and Switches 153 Two Ways to Control Evaporator Temperature 154 Thermostatic Expansion Valves 154 Equalizers and Springs / H-blocks Fixed Orifice Tubes 156 Electronic Expansion Valves 156 Evaporator Pressure Controls 157 Pressure Controls Types of Evaporator Compressor Clutch Controls 161 Pressure Cycling Switches / Thermostatic Switches / Pressure and Temperature Cycling Temperature Sensors System Protection Switches and Valves 163 Pressure Cutoff Switches / Temperature Cutoff Switches / Thermal Limiters Chapter 11: Engine Cooling Systems and Vehicle Heaters 167 Cooling System 168 Engine Cooling System Operation 168 Engine Cooling System Components 168 Liquid-cooled Engines 168 Coolants / Engine Water Jackets / Coolant Pump / Coolant Pump Drive Belts / Radiator / Radiator Fans / Thermostat / Coolant Hoses / Pressure Cap / Coolant Recovery Systems / Drains and Air Bleeds Air-Cooled Engines 178 Engine Cooling Fins / Blower / Shrouds / Oil Cooler / Thermostat Heating System 179 Heater Liquid-Cooled Engine / Heater Air-Cooled Engine Heating System Components 180 Liquid-Cooled System / Air-Cooled System Chapter 12: Air Delivery Systems 185 Air Handling Systems 186 Blowers and Motors 186 Blower Wheels / Blower Motors Air Ducts and Heater/Evaporator Cases 187 Intake Ductwork / Heater and Evaporator Cases / Output Ductwork / Vents / Independent Vents Air Doors and Operating Devices 190 Blend Door / Diverter Doors / Door Operating Devices/Cabin Filters Chapter 13: Manual HVAC Controls 199 Control System Purposes 200 Temperature Control / Humidity Control / Airflow HVAC Control System Modes 200 Manual Control Systems 203 Control System Parts / Electrical and Electronic Controls / Compressor Controls / HVAC Electrical System Protection Devices / Control System Operation Chapter 14: Automatic Temperature Control Systems..213 Automatic Control Systems 214 Types of Controls / Temperature Control Loops Electronic Temperature Control Systems 215 Automatic and Semiautomatic Control Heads / Control System Parts / Control System Operation / Computer Self-diagnosis Older Temperature Control Systems 223 Mechanical Temperature Control Systems/ Electromechanical Temperature Control Systems Chapter 15: Refrigeration System Diagnosis and Leak Detection 227 Strategy-based Diagnostics 228 The Importance of Proceeding Logically 228 The Seven-Step Troubleshooting Procedure 228 Step 1 Determine the Exact Problem 228 Talking to the Driver Step 2 Check for Obvious Problems 232 Step 3 Determine Which System Is Causing the Problem 233 Functional and Performance Tests / Leak Detection Step 4 Eliminate Other Causes of the Problem 243 Step 5 Recheck the Cause of the Problem 243 Always Perform Additional Tests / Deciding on Needed Work Step 6 Correct the Defect 246 Step 7 Recheck System Operation 246 Follow-up 246 Documentation of Repairs Chapter 16: Refrigerant Recovery, Recycling, and Handling 251 Refrigerant Service 252 Rules for Handling Refrigerants / Using a Refrigerant Identifier / Adding Refrigerant to a Partially Charged System Recovering Refrigerant 254 Recovering R-134a or R-12 / Recovering Blends and Contaminated Refrigerant / Recycling Refrigerant Evacuating Refrigeration Systems 257 Evacuation Procedure Flushing Refrigeration Systems 258 Open Loop Flushing / Closed Loop Flushing

5 Table of Contents 9 Checking and Adding Oil 259 Checking Compressor Oil Level / Adding Oil to a Charged System / Adding Oil to Replacement Components / Adding Oil to the Compressor Vacuum and Pressure Testing Refrigeration Systems 261 Vacuum Testing / Nitrogen Pressure Testing Recharging Refrigeration Systems 262 Recharging with Refrigerant Service Center/ Charging with Gauge Manifold / Refrigeration System Purging Installing an Inline Filter 264 Maintaining Refrigerant Service Centers 264 Replacing the Filter-Drier / Calibrating the Service Center's Scale / Changing the Vacuum Pump Oil / Checking for Leaks / Installing a New Tank / Adding Refrigerant from a Disposable Tank / Removing Air from Charging Cylinders Chapter 17: Hose, Line, Fitting, and O-ring Service Servicing Fittings and O-rings 270 Compression Fittings / O-ring Replacement / Spring Lock Couplings / Service Fittings Servicing Hose Fittings 273 Crimped Fittings / Hose Clamps Gasket Replacement 274 Hose Service 274 Hose Removal and Replacement Making Hoses 274 Selecting Proper Hoses / Installing and Crimping Hose Fittings Line Service 276 Line Removal and Replacement / Making Lines Chapter 18: Compressor and Clutch Service 279 Common Compressor and Clutch Problems 280 Noises / Compressor Clutch Not Engaging / Excessive Pressure / Constant Low Pressure / Occasional Low Pressure Compressor Removal and Replacement 282 Compressor Removal / Adding Oil to Compressors / Compressor Installation / Compressor Retrofitting Compressor Clutch and Electromagnet Service 284 Clutch Removal / Electromagnet and Clutch Replacement Compressor Overhaul 287 Shaft Seal Replacement / Rebuilding Compressors / Overhauling Radial Piston Compressors/ Overhauling Axial Piston Compressors / Overhauling Scroll Compressors / Capacity Control Valve Removal and Replacement / Replacing Other Compressor Components Overhauling Older Compressors 294 Chapter 19: Valve, Evaporator, Condenser, and Related Parts Service 297 Common Problems 298 Expansion Valve Failures / Orifice Tubes / Evaporator Pressure Control Valves / Compressor Cycling Switches / Evaporator / Condenser / Accumulator / Receiver-Drier Component Service 301 Expansion Valves / Evaporator Pressure Control Valves / Orifice Tubes / Compressor Cycling Switches Evaporators 303 Evaporator Cleaning / Evaporator Replacement / Afterblow Module Installation Condensers 307 Condenser Cleaning / Condenser Replacement Accumulators 307 Replacement Guidelines/ Accumulator Replacement Receiver-Driers 309 Replacement Guidelines / Receiver-Drier Replacement Systems with Multiple Component Units 309 Chapter 20: Heater and Engine Cooling System Service 313 Safety Considerations 314 Cooling System Inspection 314 Cooling System Checks Heating System Problems 320 Poor or No Heating / Too Much Heat / Coolant Leaks / Heater Problems Air-cooled Engine Engine Cooling System Problems 322 Overheating / Coolant Leaks / Causes of Air-cooled Engine Overheating / Overcooling Heater Service 323 Changing Changing Liquid Cooling System Heater Hoses and Shutoff Valves / Heater Cores Service 327 Changing Coolant and Flushing the Cooling System / Belt and Hose Replacement / Thermostat Replacement / Cooling Fan Replacement / Coolant Pump Replacement / Radiator Replacement Air Cooling System Service 333 Cleaning Fins on an Air-cooled Engine / Replacing Blower Belt / Replacing Blower and Bearing / Replacing Thermostat

6 10 Auto Heating & Air Conditioning Chapter 21: Air Delivery and Manual HVAC Control Service 337 Air Delivery and Manual Control System Problems 338 Blower Motors and Related Parts / Cabin Filter/Air Intake Filter / Ducts and Air Doors / Manual Control Panels Air Delivery and Control System Service 342 Blend Door Cable Adjustments / Removal and Replacement of Components / Checking Afterblow Modules Chapter 22: Automatic Temperature Control System Service 353 Automatic Temperature Control System Problems 354 Electronic Temperature Control Systems / Electronic Control System Self-Diagnosis Electronic Temperature Control System Testing 359 Testing Input Sensors / Testing Output Devices / Mechanical Temperature Control Systems / Electromechanical Temperature Control Systems Electronic Temperature Control System Service 360 Computer Reprogramming/Control Head/ Temperature Control Computer / Air Temperature and Sunload Sensors / Replacing Output Devices Mechanical and Electromechanical System Service 364 Adjusting Transducer Cables / Replacing System Parts / Power Servo / Amplifiers Chapter 23: Air Conditioning System Installation and Retrofitting 367 Aftermarket Air Conditioners 368 Aftermarket Air Conditioning Kits / Aftermarket Air Conditioning Considerations / Installing an Aftermarket Air Conditioner R-12 to R-134a Retrofitting 375 Whether to Retrofit / Level of Retrofit / Performing a Complete Retrofit Chapter 24: Taking the ASE Tests 385 Types of ASE Test Questions 387 One-part Questions/Two-part Questions/Negative Questions/Incomplete Sentence Questions Test Results 388 Technician Confidentiality 388 Recertification Tests 388 Certification in Refrigerant Recovery and Recycling 388 Chapter 25: Career Preparation 393 Automotive Servicing 394 Levels of Automotive Service Positions 394 Helpers / Apprentices / Certified Technicians Types of Auto Service Facilities 395 New Vehicle Dealers / Chain and Department Store Auto Service Centers / Tire, Muffler, and Other Specialty Shops / Independent Repair Shops / Fleet Agencies / Government Agencies / Self-Employment Other Opportunities in the Auto Service Industry 398 Shop Supervisor or Service Manager / Salesperson or Service Advisor / Parts Person Getting a Job 399 Finding Job Openings / Applying for the Job Appendix A: Rear Window and Mirror Defrosters 403 Defroster Components and Operation 404 Defroster Operation / Older Rear Window Defoggers Defroster Diagnosis 405 Defroster Service 406 Replacing Switches and Relays / Repairing the Window Grid Useful Tables 411 Acknowledgments 414 Glossary 415 Index 425 ASE Certification 383 ASE Tests 384 Other ASE Activities/ASE Test Windows Applying for the ASE Tests 385