Upload
trinhmien
View
215
Download
0
Embed Size (px)
Citation preview
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 ConditioningSystem Components 12
Refrigeration System Parts and Operation / Heating
System Parts and Operation / Air Delivery SystemParts and Operation
HVAC System Controls 19
Mechanical Devices
HVAC System Operation 20
Air Conditioning / Ventilating / Heating / Defrost
HVAC System History 21
Heaters / Ventilation / Air ConditioningThe 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 / EyeProtection / Foot and Hand Protection
Kinds of Accidents 29
Maintaining a Safe Workplace / Performing WorkProcedures Properly
Refrigerant Safety Precautions 34
Vapor and Liquid Refrigerants / Rules for HandlingRefrigerants
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 LiquidWaste 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
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 of Electrical
Circuits / Circuit Defects
Electromagnetism 67
Vehicle Wiring and Electrical Components 68
Wiring / Wiring Schematics / Circuit Protection
Devices / Switches / Solenoids, Relays, and MagneticClutches / 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-TemperatureRelationship
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? / RefrigerantsThe 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 ZeotropicBlends) / 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 / RefrigerationSystem 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 / SealingWashers / 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 / ConstantlyEngaged 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 EvaporatorCondensers 146
Condenser DesignAccumulators 148
Accumulator OperationReceiver-Driers 148
Desiccants
Pressure Relief Devices 150
8Auto 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
Types of Evaporator Pressure Controls
Compressor Clutch Controls 161
Pressure Cycling Switches / Thermostatic
Temperature Cycling Switches / Pressure and
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 OperatingDevices/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 SystemProtection Devices / Control System Operation
Chapter 14:
Automatic Temperature Control Systems ..213
Automatic Control Systems 214
Types of Controls / Temperature Control LoopsElectronic Temperature Control Systems 215
Automatic and Semiautomatic Control Heads /
Control System Parts / Control System Operation /
Computer Self-diagnosisOlder 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 theProblem 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 RefrigerantIdentifier / Adding Refrigerant to a Partially ChargedSystem
Recovering Refrigerant 254
Recovering R-134a or R-12 / Recovering Blends and
Contaminated Refrigerant / Recycling RefrigerantEvacuating Refrigeration Systems 257
Evacuation Procedure
Flushing Refrigeration Systems 258
Open Loop Flushing / Closed Loop Flushing
Table of Contents 9
Checking and Adding Oil 259
Checking Compressor Oil Level / Adding Oil to
a Charged System / Adding Oil to ReplacementComponents / Adding Oil to the Compressor
Vacuum and Pressure Testing RefrigerationSystems 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 / AddingRefrigerant from a Disposable Tank / Removing Air
from Charging Cylinders
Chapter 17:
Hose, Line, Fitting, and O-ring Service.... 269
Servicing Fittings and O-rings 270
Compression Fittings / O-ring Replacement / SpringLock Couplings / Service Fittings
Servicing Hose Fittings 273
Crimped Fittings / Hose ClampsGasket Replacement 274
Hose Service 274
Hose Removal and ReplacementMaking Hoses 274
Selecting Proper Hoses / Installing and CrimpingHose 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 / EvaporatorPressure Control Valves / Compressor CyclingSwitches / Evaporator / Condenser / Accumulator /Receiver-Drier
Component Service 301
Expansion Valves / Evaporator Pressure Control
Valves / Orifice Tubes / Compressor CyclingSwitches
Evaporators 303
Evaporator Cleaning / Evaporator Replacement /
Afterblow Module Installation
Condensers 307
Condenser Cleaning / Condenser ReplacementAccumulators 307
Replacement Guidelines/ Accumulator ReplacementReceiver-Driers 309
Replacement Guidelines / Receiver-Drier
Replacement
Systems with Multiple Component Units 309
Chapter 20:
Heater and Engine Cooling SystemService 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 / OvercoolingHeater Service 323
Changing Heater Hoses and Shutoff Valves /
Changing Heater Cores
Liquid Cooling System Service 327
Changing Coolant and Flushing the CoolingSystem / Belt and Hose Replacement / Thermostat
Replacement / Cooling Fan Replacement / Coolant
Pump Replacement / Radiator ReplacementAir Cooling System Service 333
Cleaning Fins on an Air-cooled Engine / ReplacingBlower Belt / Replacing Blower and Bearing /
Replacing Thermostat
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/AirIntake 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-DiagnosisElectronic 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 Temperatureand Sunload Sensors / Replacing Output Devices
Mechanical and Electromechanical System Service 364
Adjusting Transducer Cables / Replacing SystemParts / Power Servo / Amplifiers
Chapter 23:
Air Conditioning System Installation and
Retrofitting 367
Aftermarket Air Conditioners 368
Aftermarket Air Conditioning Kits / AftermarketAir Conditioning Considerations / Installing anAftermarket Air Conditioner
R-12 to R-134a Retrofitting 375
Whether to Retrofit / Level of Retrofit / Performing a
Complete Retrofit
Chapter 24:
ASE Certification 383ASE Tests 384
Other ASE Activities/ASE Test Windows
Applying for the ASE Tests 385
Taking the ASE Tests 385
Types of ASE Test Questions 387
One-part Questions/Two-part Questions/NegativeQuestions/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-EmploymentOther 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 DefoggersDefroster Diagnosis 405
Defroster Service 406
Replacing Switches and Relays / Repairing theWindow Grid
Useful Tables 411
Acknowledgments 414
Glossary 415
Index 425