AUTOMOTIVE HEATING AND

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

I chapter 1 SERVICE INFORMATION, TOOLS, AND SAFETY 1 Objectives 1 Key Terms 1 1.1 Service Information 1 1.1.1 Vehicle Identification 1 1.1.2 Service Information 3 1.2 Threaded Fasteners 4 1.2.1 Bolts and Threads 4 1.2.2 Tensile Strength of Fasteners 6 1.2.3 Nuts 6 1.2.4 Washers 7 1.3 Hand Tools 7 1.3.1 Wrenches 7, 1.3.2 Ratchets, Sockets, and Extensions 9 1.3.3 Screwdrivers 11 1.3.4 Hammers and Mallets 12 1.3.5 Pliers 13 1.3.6 Cutting Tools 14 1.4 Basic Hand Tools 16 1.4.1 Tool Sets and Accessories 17 1.4.2 Electrical Tools 17 1.4.3 Hand Tool Maintenance 18 1.4.4 Air and Electrically Operated Tools 19 1.4.5 Heating, Ventilation, and Air-Conditioning (HVAC) Special Service Tools 20 chapter 2 HAZARDOUS ENVIRONMENTAL MATERIALS 35 Objectives 35 Key Terms 35 2.1 Hazardous Waste 35 2.1.1 Definition of Hazardous Waste 35 2.1.2 Personal Protective Equipment (PPE) 35 2.2 Federal and State Laws 35 2.2.1 Occupational Safety and Health Act 35 2.2.2 EPA 35 2.2.3 Right-to-Know Laws 36 2.2.4 Resource Conservation and Recovery Act (RCRA) 36 2.2.5 Clean Air Act 36 2.3 Asbestos Hazards 37 2.3.1 OSHA Asbestos Standards 37 2.3.2 EPA Asbestos Regulations 37 2.3.3 Asbestos Handling Guidelines 37 2.4 Used Brake Fluid 38 2.4.1 Storage and Disposal of Brake Fluid 38 2.5 Used Oil 38 2.5.1 Storage and Disposal of Used Oil 38 2.6 Solvents 39 2.6.1 Effects of Chemical Poisoning 39 1.5 Safety Precautions 20 2.6.2 Regulatory Status of Hazardous 1.5.1 Personal Protective Equipment 20 1.6 Working Safe 23 1.6.1 Vehicle Protection 23 1.6.2 Lifting (Hoisting) a Vehicle Safely 23 1.6.3 Electrical Cord Safety 26 1.6.4 Jump-Starting and Battery Safety 26 1.6.5 Fire Extinguishers 27 1.6.6 Fire Blankets 28 1.6.7 First Aid and Eye Wash Stations 28 1.6.8 Hybrid Electric Vehicle Safety Issues 29 Solvents 39 2.6.3 Used Solvents 40 2.7 Coolant 40 2.8 Lead-Acid Battery Waste 40 2.8.1 Battery Disposal 41 2.8.2 Battery Handling and Storage 41 2.9 Fuel Safety and Storage 41 2.10 Airbags 41 2.11 Used Tires 42 2.12 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

chapter 3 BASICS OF HEATING AND AIR CONDITIONING 46 Objectives 46 Key Terms 46 3.1 Introduction 46 3.2 Heat 47 4.8.5 R-152A 64 4.8.6 R-290, Propane, & R-600 Butane 65 4.8.7 R-744, C02 65 4.8.8 Blends 65 4.8.9 Refrigerant Oils 65 SUMMARY 66 REVIEW QUESTIONS 66 CHAPTER QUIZ 66 3.3 Heat Measurement 47 3.3.1 Heat Intensity 47 3.3.2 Heat Quantity 49 3.4 Comfort 50 SUMMARY 51 3.4.1 Humidity 50 3.4.2 Cleanliness 50 REVIEW QUESTIONS 51 CHAPTER QUIZ 51 chapter 4 HEAT MOVEMENT THEORY 53 Objectives 53 Key Terms 53 4.1 Introduction 53 4.2 Heat Movement 54 4.2.1 Conduction 54 4.2.2 Convection 54 4.2.3 Radiation 54 4.3 States of Matter 55 4.3.1 Solid 56 4.3.2 Liquid 56 4.3.3 Gas 56 4.4 Latent and Sensible Heat 57 4.5 Boiling Points 58 4.5.1 Critical Temperature 58 chapter 5 REFRIGERANTS AND THE ENVIRONMENT 68 Objectives 68 Key Terms 68 5.1 Introduction 68 5.1.1 Ozone Depletion 68 5.1.2 Global Warming and Greenhouse Gases 69 5.2 Legislation 69 5.3 Additional Concerns 70 5.4 Recovery and Recycling 71 5.4.1 Recovering Contaminated Refrigerant 71 5.4.2 Recovery Container Certification 71 5.4.3 Small Cans 71 5.5 Refrigerants 73 summary 79 5.5.1 Alternate Refrigerants for R-12 75 5.5.2 Alternate Refrigerants, R-134A 76 5.5.3 Counterfeit and Bootleg Refrigerants 76 5.5.4 Future Refrigerants and Systems 77 5.5.5 Secondary Loop Systems 78 5.5.6 Refrigerant Safety Precautions 78 review questions 79 chapter quiz 80 4.6 Saturated Vapors and the Pressure-Temperature Relationship 59 4.7 Pressure: Gauge and Absolute 60 4.8 Refrigerants 61 4.8.1 R-12 62 4.8.2 R-22 62 4.8.3 R-134A 63 4.8.4 HFO-1234YF 64 chapter 6 MOVING HEAT: HEATING AND AIR CONDITIONING PRINCIPLES 81 Objectives 81 Key Terms 81 XI

: 7.3.2 6.1 Introduction 81 6.2 Heating Load 81 6.2.1 Seat Heaters 82 6.3 Cooling Load 82 6.4 Compression Heating 84 6.4.1 C02 Systems 84 6.5 Expansion Cooling 85 summary 86 review questions 86 chapter quiz 87 8.3 Condensers 126 8.4 Expansion Devices 128 8.4.1 Thermal Expansion Valves 128 8.4.2 Orifice Tubes 130 8.4.3 Variable Orifice Valves (VOVs) 130 8.5 Evaporators 131 8.6 Receiver-Driers and Accumulators 132 8.6.1 Accumulators 132 8.6.2 Receiver-Drier 133 8.6.3 Filters and Mufflers 134 chapter 7 AIR-CONDITIONING SYSTEMS Objectives 88 Key Terms 88 7.1 Introduction 88 7.2 Low-Side Operation 88 7.2.1 Expansion Devices 90 7.2.2 Evaporators 92 7.2.3 Accumulator 93 7.2.4 Refrigerant Charge Level 94 7.2.5 Evaporator Icing Controls 95 7.3 High-Side Operation 98 7.3.1 Compressor 98 Condensers 103 7.3.3 Receiver-Drier 106 7.3.4 High-Pressure Control 107 7.4 Lines and Hoses 108 summary 110 review questions 110 chapter quiz 110 chapter 8 AIR-CONDITIONING SYSTEM COMPONENTS 112 Objectives 112 Key Terms 112 8.1 Introduction 112 8.2 Compressors 112 88 8.7 Hoses and Lines 135 8.8 Electrical Switches and Evaporator Temperature Controls 137 8.8.1 Switches and Relays 137 8.9 Rear A/C Systems 141 8.10 Aftermarket A/C Units 142 SUMMARY 144 REVIEW QUESTIONS 144 CHAPTER QUIZ 144 chapter 9 HEATING SYSTEMS 146 Objectives 146 Key Terms 146 9.1 Introduction 146 9.2 Operation 146 9.2.1 Engine-off Heater Operation 146 9.2.2 Electric and Hybrid Vehicle Heating Systems 146 9.3 Heater Core 148 9.4 Hoses 148 9.4.1 Restrictors 150 9.5 Control Valves 150 9.6 Dual Heating Systems 150 9.7 Aftermarket Heating Systems 151 summary 152 review questions 152 chapter quiz 152 8.2.1 Piston Compressors 113 8.2.2 Compressor Clutches 119 8.2.3 Compressor Shaft Seal 123 8.2.4 Compressor Lubrication 124 8.2.5 Compressor Switches and Relief Valves 125 chapter 10 AIR MANAGEMENT SYSTEM Objectives 153 Key Terms 153 153 XH

10.1 Introduction 153 10.1.1 Controlling Air Temperature 154 10.1.2 Controlling Airflow 154 10.2 Cases and Ducts 155 10.2.1 Air Inlet and Control Door 155 10.2.2 Plenum and Control Door 157 10.2.3 Air Distribution, Control Doors, and Outlets 157 10.2.4 Dual-Zone Air Distribution 157 10.2.5 Horizontal-Split Airflow 159 10.3 Control Head 159 10.3.1 Vacuum Control Circuit 160 10.3.2 Electrical Control Circuits and Blower Motors 162 10.4 Rear Air Distribution Systems 164 10.5 Automatic Temperature Control and Semiautomatic Temperature Control 164 10.5.1 ATC Sensors 164 10.5.2 Control Device 169 10.5.3 Actuators 170 10.6 Rear Window Defroster 172 SUMMARY 172 REVIEW QUESTIONS 173 CHAPTER QUIZ 173 12.1 Introduction 189 12.1.1 A/C Service Regulations 189 12.2 A/C Pressure Checks 190 12.2.1 Service Units 190 12.2.2 Gauge Set 192 12.2.3 Connecting and Disconnecting Gauges to a System 196 12.3 Performance Test 201 12.3.1 System Temperatures 203 12.3.2 Measuring Relative Humidity 204 12.3.3 Interpreting Sight Glasses 204 12.3.4 Interpreting Performance Test Readings 206 12.3.5 Abnormal Conditions 210 12.3.6 Verifying Refrigerant Charge Level 215 12.3.7 On-VehicleTXV Tests 216 12.3.8 Electronic Diagnostic Tool 217 12.4 A/C System Refrigerant Leak Tests 219 12.4.1 Evaporator Inspection 228 12.4.2 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 174 11.1 Introduction 174 11.2 HVAC System Inspection 175 11.2.1 A/C System Inspection 175 11.3 Problem Diagnosis 180 11.4 HVAC System Problems 183 11.4.1 System Odors 184 11.4.2 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 232 13.1 Introduction 232 13.2 Heater Inspection 232 13.2.1 Coolant Circulation Checks 233 13.2.2 Heater Core Leak Check 235 13.2.3 Remove and Replace Heater Core 235 13.2.4 Bleeding Air from Core 237 13.2.5 Defroster Checks 237 13.3 HVAC Air Filter Replacement 237 13.4 AIR Management System Checks 239 13.4.1 Blend Door Operation 239 13.4.2 Cable Control System Checks and Adjustments 240 13.4.3 Vacuum Control System Checks 241 SUMMARY 244 REVIEW QUESTIONS 244 CHAPTER QUIZ 245 contents xiii

chapter 14 HVAC SYSTEM ELECTRICAL AND ELECTRONIC CONTROLS: THEORY, INSPECTION, DIAGNOSIS, AND REPAIR 246 Objectives 246 Key Terms 246 14.1 Introduction 246 14.2 Basic Electricity 246 14.2.1 System Components 248 14.3 Basic Electronics 251 14.3.1 Sensors 251 14.3.2 Control Module 252 14.3.3 Actuators 256 14.3.4 Multiplex and CAN Systems 256 14.4 HVAC Circuits 258 14.4.1 Power Supply 258 14.4.2 Compressor Clutch Circuit 258 14.4.3 Blower Motor Circuit 260 14.4.4 Electronic Controlled Variable Compressor 261 14.4.5 Cooling Fan Circuit 263 14.4.6 Hybrid Vehicle Circuits 264 14.4.7 Climate-Controlled Seats 265 14.5 Electrical Circuit Problems 265 14.5.1 Open Circuits 265 14.5.2 High-Resistance Circuits 265 14.5.3 Shorted Circuits 265 14.5.4 Grounded Circuits 266 14.5.5 EMI, RFI 266 14.6 Measuring Electrical Values 267 14.6.1 Measuring Voltage 268 14.6.2 Source Voltage 271 14.6.3 Measuring Resistance 273 14.6.4 Measuring Amperage 273 14.6.5 Interpreting Measurements 276 14.6.6 Advanced Testing Methods, Electronic 14.7 Electrical System Repair 284 14.7.1 Electrical Component Replacement 286 summary 287 review questions 287 chapter quiz 288 chapter 15 REFRIGERANT SERVICE OPERATIONS 289 Objectives 289 Key Terms 289 15.1 Introduction 289 15.1.1 Gauge Pressures 289 15.2 Preventive Maintenance and Adjustment Operations 289 15.2.1 A/C Service and the Clean Air Act 290 15.3 A/C Service Operations 291 15.3.1 Refrigerant Contamination 292 15.3.2 Refrigerant Identification 293 15.3.3 Refrigerant Recovery 295 15.3.4 Recycling Refrigerant 298 15.3.5 Flushing an A/C System 301 15.3.6 Installing an Inline Filter 303 15.3.7 Checking and Correcting Oil Levels 305 15.3.8 Evacuating a System 307 15.3.9 Recharging a System 310 15.4 Retrofitting R-134A into an R-12 System 317 15.4.1 Section 609, EPA Retrofit Requirements 317 15.4.2 Refrigerant Choice for Retrofit 317 15.4.3 Possible Retrofit Problems 317 15.4.4 Retrofit Procedure 318 15.5 Using and Installing Sealants and Stop Leaks 322 summary 323 review questions 323 chapter quiz 324 Self-Diagnosis 277 14.6.7 OBD-II 281 14.6.8 Scan Tools 282 14.6.9 Variable Compressor Diagnosis 283 14.6.10 ECM Flashing 283 14.6.11 Actuator Motor Calibration 284 chapter 16 A/C SYSTEM REPAIR 325 Objectives 325 Key Terms 325 XIV

16.1 Introduction 325 16.1.1 Compressor Diagnosis 325 16.2 Compressor Repair 326 16.2.1 Compressor R&R 327 16.2.2 Clutch and Clutch Coil R&R 331 16.2.3 Compressor Shaft Seal R&R 336 16.2.4 Compressor Repair 342 16.2.5 Compressor Bench Checks 342 16.2.6 Compressor Oil Level Checks 344 16.3 Hose and Fitting Repair 346 16.3.1 Fitting Repair 346 16.3.2 Line Replacement 350 16.3.3 Hose Repair and Makeup 350 16.4 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 387 18.1 Introduction 387 18.2 Preventive Maintenance Operations 387 18.2.1 Coolant Level 388 18.2.2 Coolant Mixtures 389 18.2.3 Coolant Condition 390 18.2.4 Changing Coolant 393 18.2.5 Air Locks 396 18.2.6 Drive Belt Inspection and Replacement 397 18.2.7 Hose Inspection and Replacement 403 18.3 Trouble Diagnosis 404 18.3.1 Cooling System Inspection 405 chapter 17 COOLING SYSTEM THEORY 361 Objectives 361 Key Terms 361 17.1 Introduction 361 17.2 Water Jackets 362 17.3 Thermostat 362 17.4 Water Pump 365 17.4.1 Drive Belt 367 17.5 Radiator 370 17.5.1 Pressure Cap 371 18.3.2 Pressure Tests 410 18.3.3 Combustion Leak Checks 413 18.3.4 Thermostat Check 415 18.3.5 Fan Clutch Test 415 18.3.6 Electric Fan Tests 416 18.3.7 Water-Pump Test 416 18.4 Cooling System Service and Repair 416 18.4.1 Flushing a System 417 18.4.2 Component Replacement 419 summary 424 review questions 424 chapter quiz 425 17.5.2 Coolant Recovery Reservoir 372 17.5.3 Cooling Modules 373 17.6 Fan 374 17.6.1 Fan Clutch 374 17.6.2 Electric Fans 375 17.7 Hoses 377 17.8 Hybrid Vehicle Cooling System 379 17.9 Gauges 380 17.10 Coolant 381 17.11 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-12 433 XV

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