Auto Heating and Air Conditioning Technology

by Johanson, Chris

• ISBN13: 9781590702765
• ISBN10: 159070276X
• Format: Paperback
• Copyright: 2003-08-01
• Publisher: Goodheart-Willcox Pub
• More Book Details
• Purchase Benefits

Summary

Contains the latest information on vehicle heating, ventilation, and air conditioning systems.

Table of Contents

Introduction to Automotive Heating, Air Conditioning, and Ventilation	11	(16)
Heating, Ventilating, and Air Conditioning (HVAC) Systems	12	(1)
Why Is It Called HVAC?
Major Heating, Ventilation, and Air Conditioning System Components	12	(7)
Refrigeration System Parts and Operation
Heating System Parts and Operation
Air Delivery System Parts and Operation
HVAC System Controls	19	(1)
Mechanical Devices
HVAC System Operation	20	(1)
Air Conditioning
Ventilating
Heating
Defrost
HVAC System History	21	(2)
Heaters
Ventilation
Air Conditioning
The Air Conditioner and the Ozone Layer	23	(4)
Shop Safety and Environmental Protection	27	(12)
Causes of Accidents	28	(1)
Personal Safety Equipment	28	(1)
Proper Clothing and Protective Equipment
Eye Protection
Foot and Hand Protection
Kinds of Accidents	28	(4)
Maintaining a Safe Workplace
Performing Work Procedures Properly
Refrigerant Safety Precautions	32	(1)
Vapor and Liquid Refrigerants
Rules for Handling Refrigerants
First Aid for Refrigerant Exposure	33	(1)
First Aid for Skin Exposure
First Aid for Eye Exposure
First Aid for Breathing Difficulty
Preventing Environmental Damage	33	(6)
Prevent Solid Waste Contamination
Prevent Liquid Waste Contamination
Prevent Gaseous Waste Contamination
The Environmental Protection Agency
HVAC Tools, Equipment, and Service Information	39	(24)
Diagnostic and Test Equipment	40	(7)
Gauge Manifolds
Temperature Gauges
Leak Detectors
Refrigerant Identifiers
Electrical Test Equipment
Belt Tension Gauges
Vacuum Pumps/Gauges
HVAC System Service Tools	47	(3)
Compressor Service Tools
Compressor Clutch Service Tools
Hose Tools
Orifice Tube Tools
Oil Injectors
Refrigerant Service Equipment	50	(4)
Recovery/Recycling Equipment
Flushing Equipment
Evacuation Pumps
Recharging Equipment
Air Purging Equipment
Engine Cooling System Test Equipment	54	(2)
Pressure and Leak Testers
Antifreeze Testers
Combustion Leak Testers
Service Literature	56	(4)
Factory Manual
General Manual
Specialized Manual
Technical Service Bulletins
Telephone Hotlines
Computerized Assistance	60	(3)
Manuals on CD-ROM
Internet Resources
HVAC Electrical and Electronic Fundamentals	63	(18)
Electrical Basics	64	(3)
Conductors and Insulators
Electrical Measurements
Direct and Alternating Current
Types of Electrical Circuits
Circuit Defects
Electromagnetism	67	(1)
Vehicle Wiring and Electrical Components	68	(7)
Wiring
Wiring Schematics
Circuit Protection Devices
Switches
Solenoids, Relays, and Magnetic Clutches
Motors
Resistors
Capacitors
Basic Electrical Diagnosis	75	(1)
Electrical Device Not Working
Electrical Device on at All Times
Vehicle Computers	75	(6)
Semiconductor Materials
Computer Circuits
Control Loops
Main Computer Sections
Computer Diagnostic Outputs
Principles of Refrigeration	81	(16)
The Purpose of Refrigeration	82	(1)
Basic Principles of Refrigeration	82	(3)
Heat and Cold
Heat Transfer
Change of State
Sensible and Latent Heat
The Pressure-Temperature Relationship
Refrigeration Components	85	(6)
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	(6)
Cooling Phase---Evaporator
Pressure Increase Phase---Compressor
Heat Transfer Phase---Condenser
Pressure Decrease Phase---Flow Restrictor
Factors That Affect System Performance
Refrigerants, Refrigerant Oils, and Related Chemicals	97	(12)
Refrigerant Purposes	98	(1)
Refrigerants and Governmental Regulation	98	(1)
Montreal Protocol
Clean Air Act
Types of Refrigerants	99	(2)
R-134a
R-12 (Freon)
R-134a versus R-12
Refrigerant Classification	101	(1)
Blended Refrigerants (Azeotropic and Zeotropic Blends)
Drop-in Refrigerants
Replacement Refrigerants	102	(1)
Choosing a Replacement Refrigerant
SNAP Program
Refrigerant Oils	103	(1)
Types of Refrigerant Oil
Other Refrigeration System Chemicals	104	(5)
Desiccants
Flushing Compounds
Leak Detector Dyes
Evaporator Surface Cleaners
Hoses, Lines, Fittings, and Seals	109	(12)
Hoses and Lines	110	(2)
Hoses
Metal Lines
Combination Hose and Line Assemblies
Hose and Line Attachments
Hose and Line Size Specifications
Refrigeration System Fittings	112	(4)
Compression Fittings
Crimp Fittings
Spring Lock Couplings
Screw Type Hose Clamps
Service Fittings
Making Hoses, Lines, and Fittings	116	(1)
Refrigeration Sealing Devices	116	(5)
Compressor Shaft Seals
O-ring Seals
Sealing Washers
Gaskets
Compressors, Clutches, and Drives	121	(22)
Compressor Purposes	122	(1)
Basic Compressor Parts	122	(1)
Types of Compressors	122	(8)
Piston Compressors
Rotary Vane Compressors
Scroll Compressors
Compressor Capacity Control Valves	130	(1)
Compressor Drives and Clutches	130	(5)
Compressor Drive
Compressor Clutches
Compressor Clutch Control Systems
Compressor Makes and Models	135	(8)
Bosch
Calsonic
Chrysler
Frigidaire (General Motors-Delphi)
Ford
Hitachi
Keihin
Matsushita/Panasonic
Mitsubishi
Nihon/Nihon Radiator
Nippondenso
Sanden/Sankyo
Seiko-Seki
Tecumseh/York
Zexel/Diesel Kiki
Older Compressors
Evaporators, Condensers, Accumulators, and Receiver-Driers	143	(10)
Evaporators	144	(2)
Evaporator Design and Construction
Types of Evaporators
Parts Attached to the Evaporator
Condensers	146	(2)
Condenser Design
Accumulators	148	(1)
Accumulator Operation
Receiver-Driers	148	(2)
Desiccants
Pressure Relief Devices	150	(3)
Control Valves and Switches	153	(14)
Two Ways to Control Evaporator Temperature	154	(1)
Thermostatic Expansion Valves	154	(2)
Equalizers and Springs
H-blocks
Fixed Orifice Tubes	156	(1)
Evaporator Pressure Controls	157	(4)
Types of Evaporator Pressure Controls
Compressor Clutch Controls	161	(2)
Pressure Cycling Switches
Thermostatic Temperature Cycling Switches
Pressure and Temperature Sensors
System Protection Switches and Valves	163	(4)
Pressure Cutoff Switches
Temperature Cutoff Switches
Thermal Limiters
Engine Cooling Systems and Vehicle Heaters	167	(18)
Cooling System	168	(1)
Engine Cooling System Operation	168	(1)
Engine Cooling System Components	168	(1)
Liquid-cooled Engines	168	(10)
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	(1)
Engine Cooling Fins
Blower
Shrouds
Oil Cooler
Thermostat
Heating System	179	(1)
Heater---Liquid-Cooled Engine
Heater---Air-Cooled Engine
Heating System Components	180	(5)
Liquid-Cooled System
Air-Cooled System
Air Delivery Systems	185	(14)
Air Handling Systems	186	(1)
Blowers and Motors	186	(1)
Blower Wheels
Blower Motors
Air Ducts and Heater/Evaporator Cases	187	(3)
Intake Ductwork
Heater and Evaporator Cases
Output Ductwork
Vents
Independent Vents
Air Doors and Operating Devices	190	(9)
Blend Door
Diverter Doors
Door Operating Devices
Intake Air Filters
Manual HVAC Controls	199	(14)
Control System Purposes	200	(1)
Temperature Control
Humidity Control
Airflow Control
HVAC Control System Modes	200	(3)
Manual Control Systems	203	(10)
Control System Parts
Electrical and Electronic Controls
Compressor Controls
HVAC Electrical System Protection Devices
Control System Operation
Automatic Temperature Control Systems	213	(14)
Automatic Control Systems	214	(1)
Types of Controls
Temperature Control Loops
Electronic Temperature Control Systems	215	(8)
Automatic and Semiautomatic Control Heads
Control System Parts
Control System Operation
Computer Self-diagnosis
Older Temperature Control Systems	223	(4)
Mechanical Temperature Control Systems
Electromechanical Temperature Control Systems
Refrigeration System Diagnosis and Leak Detection	227	(24)
Strategy-based Diagnostics	228	(1)
The Importance of Proceeding Logically	228	(1)
The Seven-Step Troubleshooting Procedure	228	(1)
Step 1---Determine the Exact Problem	228	(4)
Talking to the Driver
Step 2---Check for Obvious Problems	232	(1)
Step 3---Determine Which System Is Causing the Problem	233	(11)
Functional and Performance Tests
Leak Detection
Step 4---Eliminate Other Causes of the Problem	244	(1)
Step 5---Recheck the Cause of the Problem	244	(4)
Always Perform Additional Tests
Deciding on Needed Work
Step 6---Correct the Defect	248	(1)
Step 7---Recheck System Operation	248	(1)
Follow-up	248	(3)
Documentation of Repairs
Refrigerant Recovery, Recycling, and Handling	251	(18)
Refrigerant Service	252	(2)
Rules for Handling Refrigerants
Using a Refrigerant Identifier
Adding Refrigerant to a Partially Charged System
Recovering Refrigerant	254	(3)
Recovering R-134a or R-12
Recovering Blends and Contaminated Refrigerant
Recycling Refrigerant
Evacuating Refrigeration Systems	257	(1)
Evacuation Procedure
Flushing Refrigeration Systems	258	(1)
Open Loop Flushing
Closed Loop Flushing
Checking and Adding Oil	259	(2)
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	(1)
Vacuum Testing
Nitrogen Pressure Testing
Recharging Refrigeration Systems	262	(2)
Recharging with Refrigerant Service Center
Charging with Gauge Manifold
Refrigeration System Purging
Installing an Inline Filter	264	(1)
Maintaining Refrigerant Service Centers	264	(5)
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
Hose, Line, Fitting, and O-ring Service	269	(10)
Servicing Fittings and O-rings	270	(3)
Compression Fittings
O-ring Replacement
Spring Lock Couplings
Service Fittings
Servicing Hose Fittings	273	(1)
Crimped Fittings
Hose Clamps
Gasket Replacement	274	(1)
Hose Service	274	(1)
Hose Removal and Replacement
Making Hoses	274	(2)
Selecting Proper Hoses
Installing and Crimping Hose Fittings
Line Service	276	(3)
Line Removal and Replacement
Making Lines
Compressor and Clutch Service	279	(18)
Common Compressor and Clutch Problems	280	(2)
Noises
Compressor Clutch Not Engaging
Excessive Pressure
Constant Low Pressure
Occasional Low Pressure
Compressor Removal and Replacement	282	(2)
Compressor Removal
Adding Oil to Compressors
Compressor Installation
Compressor Retrofitting
Compressor Clutch and Electromagnet Service	284	(3)
Clutch Removal
Electromagnet and Clutch Replacement
Compressor Overhaul	287	(7)
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	(3)
Valve, Evaporator, Condenser, and Related Parts Service	297	(16)
Common Problems	298	(3)
Expansion Valve Failures
Orifice Tubes
Evaporator Pressure Control Valves
Compressor Cycling Switches
Evaporator
Condenser
Accumulator
Receiver-Drier
Component Service	301	(2)
Expansion Valves
Evaporator Pressure Control Valves
Orifice Tubes
Compressor Cycling Switches
Evaporators	303	(4)
Evaporator Cleaning
Evaporator Replacement
Afterblow Module Installation
Condensers	307	(1)
Condenser Cleaning
Condenser Replacement
Accumulators	307	(2)
Replacement Guidelines
Accumulator Replacement
Receiver-Driers	309	(1)
Replacement Guidelines
Receiver-Drier Replacement
Systems with Multiple Component Units	309	(4)
Heater and Engine Cooling System Service	313	(24)
Safety Considerations	314	(1)
Cooling System Inspection	314	(6)
Cooling System Checks
Heating System Problems	320	(2)
Poor or No Heating
Too Much Heat
Coolant Leaks
Heater Problems---Air-cooled Engine
Engine Cooling System Problems	322	(1)
Overheating
Coolant Leaks
Causes of Air-cooled Engine Overheating
Overcooling
Heater Service	323	(4)
Changing Heater Hoses and Shutoff Valves
Changing Heater Cores
Liquid Cooling System Service	327	(6)
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	(4)
Cleaning Fins on an Air-cooled Engine
Replacing Blower Belt
Replacing Blower and Bearing
Replacing Thermostat
Air Delivery and Manual HVAC Control Service	337	(16)
Air Delivery and Manual Control System Problems	338	(4)
Blower Motors and Related Parts
Ducts and Air Doors
Manual Control Panels
Air Delivery and Control System Service	342	(11)
Blend Door Cable Adjustments
Removal and Replacement of Components
Checking Afterblow Modules
Automatic Temperature Control System Service	353	(14)
Automatic Temperature Control System Problems	354	(5)
Electronic Temperature Control Systems
Electronic Control System Self-Diagnosis
Electronic Temperature Control System Testing	359	(1)
Testing Input Sensors
Testing Output Devices
Mechanical Temperature Control Systems
Electromechanical Temperature Control Systems
Electronic Temperature Control System Service	360	(4)
Computer Reprogramming
Control Head
Temperature Control Computer
Air Temperature and Sunload Sensors
Replacing Output Devices
Mechanical and Electromechanical System Service	364	(3)
Adjusting Transducer Cables
Replacing System Parts
Power Servo
Amplifiers
Air Conditioning System Installation and Retrofitting	367	(16)
Aftermarket Air Conditioners	368	(7)
Aftermarket Air Conditioning Kits
Aftermarket Air Conditioning Considerations
Installing an Aftermarket Air Conditioner
R-12 to R-134a Retrofitting	375	(8)
Whether to Retrofit
Level of Retrofit
Performing a Complete Retrofit
ASE Certification	383	(10)
Reasons for ASE Tests	384	(1)
Applying for the ASE Tests	384	(2)
Preparing for the ASE Tests	386	(1)
Taking the ASE Tests	386	(1)
Types of ASE Test Questions	386	(3)
One-part Question
Two-part Question
Negative Questions
Incomplete Sentence Questions
The ASE Heating and Air Conditioning Test
Test Results	389	(1)
Recertification Tests	390	(1)
Certification in Refrigerant Recovery and Recycling	391	(2)
Career Preparation	393	(10)
Automotive Servicing	394	(1)
Levels of Automotive Service Positions	394	(1)
Helpers
Apprentices
Certified Technicians
Types of Auto Service Facilities	395	(3)
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	(1)
Shop Supervisor or Service Manager
Salesperson or Service Advisor
Parts Person
Getting a Job	399	(4)
Finding Job Openings
Applying for the Job
Appendix A: Rear Window and Mirror Defrosters	403	(8)
Defroster Components and Operation	404	(1)
Defroster Operation
Older Rear Window Defoggers
Defroster Diagnosis	405	(1)
Defroster Service	406	(5)
Replacing Switches and Relays
Repairing the Window Grid
Useful Tables	411	(3)
Acknowledgments	414	(1)
Glossary	415	(10)
Index	425