AUTOMOTIVE HEATING AND

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1 AUTOMOTIVE HEATING AND AIR CONDITIONING SIXTH EDITION Tom Birch Prentice Hall Boston Columbus Indianapolis New York San Francisco Upper Saddle River Amsterdam Cape Town Dubai London Madrid Milan Munich Paris Montreal Toronto Delhi Mexico City Sao Paulo Sydney Hong Kong Seoul Singapore Taipei Tokyo

2 I chapter 1 SERVICE INFORMATION, TOOLS, AND SAFETY 1 Objectives 1 Key Terms Service Information Vehicle Identification Service Information Threaded Fasteners Bolts and Threads Tensile Strength of Fasteners Nuts Washers Hand Tools Wrenches 7, Ratchets, Sockets, and Extensions Screwdrivers Hammers and Mallets Pliers Cutting Tools Basic Hand Tools Tool Sets and Accessories Electrical Tools Hand Tool Maintenance Air and Electrically Operated Tools Heating, Ventilation, and Air-Conditioning (HVAC) Special Service Tools 20 chapter 2 HAZARDOUS ENVIRONMENTAL MATERIALS 35 Objectives 35 Key Terms Hazardous Waste Definition of Hazardous Waste Personal Protective Equipment (PPE) Federal and State Laws Occupational Safety and Health Act EPA Right-to-Know Laws Resource Conservation and Recovery Act (RCRA) Clean Air Act Asbestos Hazards OSHA Asbestos Standards EPA Asbestos Regulations Asbestos Handling Guidelines Used Brake Fluid Storage and Disposal of Brake Fluid Used Oil Storage and Disposal of Used Oil Solvents Effects of Chemical Poisoning Safety Precautions Regulatory Status of Hazardous Personal Protective Equipment Working Safe Vehicle Protection Lifting (Hoisting) a Vehicle Safely Electrical Cord Safety Jump-Starting and Battery Safety Fire Extinguishers Fire Blankets First Aid and Eye Wash Stations Hybrid Electric Vehicle Safety Issues 29 Solvents Used Solvents Coolant Lead-Acid Battery Waste Battery Disposal Battery Handling and Storage Fuel Safety and Storage Airbags Used Tires Air-Conditioning Refrigerant Oil 42 Waste Chart 44 summary 33 review questions 33 chapter quiz 33 SUMMARY 44 REVIEW QUESTIONS 45 CHAPTER QUIZ 45 X

3 chapter 3 BASICS OF HEATING AND AIR CONDITIONING 46 Objectives 46 Key Terms Introduction Heat R-152A R-290, Propane, & R-600 Butane R-744, C Blends Refrigerant Oils 65 SUMMARY 66 REVIEW QUESTIONS 66 CHAPTER QUIZ Heat Measurement Heat Intensity Heat Quantity Comfort 50 SUMMARY Humidity Cleanliness 50 REVIEW QUESTIONS 51 CHAPTER QUIZ 51 chapter 4 HEAT MOVEMENT THEORY 53 Objectives 53 Key Terms Introduction Heat Movement Conduction Convection Radiation States of Matter Solid Liquid Gas Latent and Sensible Heat Boiling Points Critical Temperature 58 chapter 5 REFRIGERANTS AND THE ENVIRONMENT 68 Objectives 68 Key Terms Introduction Ozone Depletion Global Warming and Greenhouse Gases Legislation Additional Concerns Recovery and Recycling Recovering Contaminated Refrigerant Recovery Container Certification Small Cans Refrigerants 73 summary Alternate Refrigerants for R Alternate Refrigerants, R-134A Counterfeit and Bootleg Refrigerants Future Refrigerants and Systems Secondary Loop Systems Refrigerant Safety Precautions 78 review questions 79 chapter quiz Saturated Vapors and the Pressure-Temperature Relationship Pressure: Gauge and Absolute Refrigerants R R R-134A HFO-1234YF 64 chapter 6 MOVING HEAT: HEATING AND AIR CONDITIONING PRINCIPLES 81 Objectives 81 Key Terms 81 XI

4 : Introduction Heating Load Seat Heaters Cooling Load Compression Heating C02 Systems Expansion Cooling 85 summary 86 review questions 86 chapter quiz Condensers Expansion Devices Thermal Expansion Valves Orifice Tubes Variable Orifice Valves (VOVs) Evaporators Receiver-Driers and Accumulators Accumulators Receiver-Drier Filters and Mufflers 134 chapter 7 AIR-CONDITIONING SYSTEMS Objectives 88 Key Terms Introduction Low-Side Operation Expansion Devices Evaporators Accumulator Refrigerant Charge Level Evaporator Icing Controls High-Side Operation Compressor 98 Condensers Receiver-Drier High-Pressure Control Lines and Hoses 108 summary 110 review questions 110 chapter quiz 110 chapter 8 AIR-CONDITIONING SYSTEM COMPONENTS 112 Objectives 112 Key Terms Introduction Compressors Hoses and Lines Electrical Switches and Evaporator Temperature Controls Switches and Relays Rear A/C Systems Aftermarket A/C Units 142 SUMMARY 144 REVIEW QUESTIONS 144 CHAPTER QUIZ 144 chapter 9 HEATING SYSTEMS 146 Objectives 146 Key Terms Introduction Operation Engine-off Heater Operation Electric and Hybrid Vehicle Heating Systems Heater Core Hoses Restrictors Control Valves Dual Heating Systems Aftermarket Heating Systems 151 summary 152 review questions 152 chapter quiz Piston Compressors Compressor Clutches Compressor Shaft Seal Compressor Lubrication Compressor Switches and Relief Valves 125 chapter 10 AIR MANAGEMENT SYSTEM Objectives 153 Key Terms XH

5 10.1 Introduction Controlling Air Temperature Controlling Airflow Cases and Ducts Air Inlet and Control Door Plenum and Control Door Air Distribution, Control Doors, and Outlets Dual-Zone Air Distribution Horizontal-Split Airflow Control Head Vacuum Control Circuit Electrical Control Circuits and Blower Motors Rear Air Distribution Systems Automatic Temperature Control and Semiautomatic Temperature Control ATC Sensors Control Device Actuators Rear Window Defroster 172 SUMMARY 172 REVIEW QUESTIONS 173 CHAPTER QUIZ Introduction A/C Service Regulations A/C Pressure Checks Service Units Gauge Set Connecting and Disconnecting Gauges to a System Performance Test System Temperatures Measuring Relative Humidity Interpreting Sight Glasses Interpreting Performance Test Readings Abnormal Conditions Verifying Refrigerant Charge Level On-VehicleTXV Tests Electronic Diagnostic Tool A/C System Refrigerant Leak Tests Evaporator Inspection Vacuum Pump Leak Tests 229 summary 230 review questions 230 chapter quiz 231 chapter 11 HVAC SYSTEM INSPECTION AND TROUBLE DIAGNOSIS PROCEDURES 174 Objectives 174 Key Terms Introduction HVAC System Inspection A/C System Inspection Problem Diagnosis HVAC System Problems System Odors Noise Problems 186 SUMMARY 187 REVIEW QUESTIONS 187 CHAPTER QUIZ 187 chapter 12 A/C SYSTEM INSPECTION AND DIAGNOSIS 189 Objectives 189 Key Terms 189 chapter 13 HEATING AND AIR MANAGEMENT SYSTEMS INSPECTION AND DIAGNOSIS 232 Objectives 232 Key Terms Introduction Heater Inspection Coolant Circulation Checks Heater Core Leak Check Remove and Replace Heater Core Bleeding Air from Core Defroster Checks HVAC Air Filter Replacement AIR Management System Checks Blend Door Operation Cable Control System Checks and Adjustments Vacuum Control System Checks 241 SUMMARY 244 REVIEW QUESTIONS 244 CHAPTER QUIZ 245 contents xiii

6 chapter 14 HVAC SYSTEM ELECTRICAL AND ELECTRONIC CONTROLS: THEORY, INSPECTION, DIAGNOSIS, AND REPAIR 246 Objectives 246 Key Terms Introduction Basic Electricity System Components Basic Electronics Sensors Control Module Actuators Multiplex and CAN Systems HVAC Circuits Power Supply Compressor Clutch Circuit Blower Motor Circuit Electronic Controlled Variable Compressor Cooling Fan Circuit Hybrid Vehicle Circuits Climate-Controlled Seats Electrical Circuit Problems Open Circuits High-Resistance Circuits Shorted Circuits Grounded Circuits EMI, RFI Measuring Electrical Values Measuring Voltage Source Voltage Measuring Resistance Measuring Amperage Interpreting Measurements Advanced Testing Methods, Electronic 14.7 Electrical System Repair Electrical Component Replacement 286 summary 287 review questions 287 chapter quiz 288 chapter 15 REFRIGERANT SERVICE OPERATIONS 289 Objectives 289 Key Terms Introduction Gauge Pressures Preventive Maintenance and Adjustment Operations A/C Service and the Clean Air Act A/C Service Operations Refrigerant Contamination Refrigerant Identification Refrigerant Recovery Recycling Refrigerant Flushing an A/C System Installing an Inline Filter Checking and Correcting Oil Levels Evacuating a System Recharging a System Retrofitting R-134A into an R-12 System Section 609, EPA Retrofit Requirements Refrigerant Choice for Retrofit Possible Retrofit Problems Retrofit Procedure Using and Installing Sealants and Stop Leaks 322 summary 323 review questions 323 chapter quiz 324 Self-Diagnosis OBD-II Scan Tools Variable Compressor Diagnosis ECM Flashing Actuator Motor Calibration 284 chapter 16 A/C SYSTEM REPAIR 325 Objectives 325 Key Terms 325 XIV

7 16.1 Introduction Compressor Diagnosis Compressor Repair Compressor R&R Clutch and Clutch Coil R&R Compressor Shaft Seal R&R Compressor Repair Compressor Bench Checks Compressor Oil Level Checks Hose and Fitting Repair Fitting Repair Line Replacement Hose Repair and Makeup A/C System Component Replacement 356 summary 359 review questions 360 chapter quiz 360 chapter 18 COOLING SYSTEM INSPECTION, TROUBLE DIAGNOSIS, AND SERVICE 387 Objectives 387 Key Terms Introduction Preventive Maintenance Operations Coolant Level Coolant Mixtures Coolant Condition Changing Coolant Air Locks Drive Belt Inspection and Replacement Hose Inspection and Replacement Trouble Diagnosis Cooling System Inspection 405 chapter 17 COOLING SYSTEM THEORY 361 Objectives 361 Key Terms Introduction Water Jackets Thermostat Water Pump Drive Belt Radiator Pressure Cap Pressure Tests Combustion Leak Checks Thermostat Check Fan Clutch Test Electric Fan Tests Water-Pump Test Cooling System Service and Repair Flushing a System Component Replacement 419 summary 424 review questions 424 chapter quiz Coolant Recovery Reservoir Cooling Modules Fan Fan Clutch Electric Fans Hoses Hybrid Vehicle Cooling System Gauges Coolant Engine Block Heater 384 summary 385 review questions 385 chapter quiz 385 appendix A ASE CERTIFICATION AND TASK LIST (A7) 427 appendix B TEMPERATURE-PRESSURE CHARTS 430 appendix C A/C SERVICE PROCEDURE DOCUMENTS 431 appendix D EPA SNAP-APPROVED REFRIGERANTS AS SUBSTITUTES FOR CFC XV

8 appendix E POTENTIAL COMPRESSOR PROBLEMS WITH R-134A 435 appendix F ENGLISH-METRIC CONVERSION TABLE 436 appendix G BOLT TORQUE TIGHTENING CHART 437 appendix H REFRIGERANT NUMBERING SYSTEM 438 appendix J "HOW TO" SERVICE OPERATIONS 440 appendix K KEY TO PROBLEM SOLVING 442 ENGLISH-LANGUAGE GLOSSARY 444 SPANISH GLOSSARY 450 INDEX 457 appendix I MEASURING TEMPERATURES USING AN INFRARED THERMOMETER 439 XVI

AUTOMOTIVE SPECIALIZATION (Air Conditioning and Heating) STUDENT GRADE RECORD Career & Technical Education

AUTOMOTIVE SPECIALIZATION (Air Conditioning and Heating) STUDENT GRADE RECORD Career & Technical Education STUDENT GRADE RECORD Career & Technical Education Course Outline Modules Windham Module Test Module Competenc y Rating WINDHAM SCHOOL DISTRICT 1. CTE Orientation 2. Introduction to Automotive Heating,