Today_s Technician_ Automotive Heating & Air Conditioning Classroom Manual and Shop Manual

1075 Pages·6·74.79 MB·English

by  Mark Schnubel

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Classroom Manual
for Automotive Heating
& Air Conditioning
Copyright 2017 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s).
Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
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Copyright 2017 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s).
Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
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Classroom Manual
for Automotive Heating
& Air Conditioning
Mark Schnubel
Naugatuck Valley Community College
Waterbury, Connecticut
Sixth Edition
Australia • Canada • Mexico • Singapore • Spain • United Kingdom • United States
Copyright 2017 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s).
Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
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Today’s Technician™: Classroom Manual © 2017, 2013 Cengage Learning
for Automotive Heating & Air Conditioning, WCN: 02-200-203
Sixth Edition
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Mark Schnubel
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Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Chapter 1 Heating and Air Conditioning—History and the Environment . . . 1
• Introduction 1 • Air Conditioning Defined 2 • Refrigeration 2 • Historical Development of Refrigeration 2
• Refrigerant and the Environment 4 • The Ozone Hole 7 • Effects of Loss of Ozone on Human Health 9
• Climate Change and the Greenhouse Effect 11 • The Clean Air Act 15
• Stratospheric Ozone Protection—Title VI 16 • Ozone Protection Regulations 16
• Refrigerant HFO-1234yf (R-1234yf) 17 • Technician Certification 20
• Injuries as a Result of High Pressure 20 • Special Safety Precautions 21 • Antifreeze/Coolant 23
• Hazardous Materials 24 • Breathing Toxic Gases 26 • The Industry 27 • ASE Certification 28
• EPA Certification 30 • Cost of Operation 31 • Summary 31 • Terms to Know 31 • Review Questions 32
Chapter 2 Temperature and Pressure Fundamentals . . . . . . . . . . . . . . . . 33
• Introduction 33 • Elements and Matter 33 • The Atom 34 • The Molecule 35 • Chemical Compounds 35
• Heat and Cold 37 • Sensible Heat of a Solid 38 • Melting or Fusion 38 • Sensible Heat of a Liquid 39
• Evaporation 39 • Specific Heat 42 • Latent Heat of Fusion 43 • Latent Heat of Vaporization 43
• Heat Flow 44 • Radiation 44 • Conduction 45 • Convection 46 • Personal Comfort and Convenience 46
• Specific Gravity 52 • Gas Laws 52 • Summary 55 • Terms to Know 55 • Review Questions 55
Chapter 3 Electricity and Electronic Fundamentals . . . . . . . . . . . . . . . . . 57
• Introduction 57 • Electrical Principles 57 • Fuses and Circuit Breakers 67 • Circuit Resistance 68
• Diodes 70 • Relays 71 • Blower Motor 73 • Electromagnetic Clutch 78 • Summary 80 • Terms to Know 80
• Review Questions 80
Chapter 4 Engine Cooling and Comfort Heating Systems . . . . . . . . . . . . 82
• Introduction 82 • The Cooling System 82 • Heat Measurement 84 • Radiator 85 • Pressure Cap 89
• Coolant Recovery System 91 • Engine Block and Cylinder Head Coolant Passages 95 • Coolant Pump 95
• Fan Shrouds, Air Baffles, and Seals 100 • Thermostat 101 • Pulley and Belt 109 • Fans 112
• Hoses and Clamps 120 • Heater System 121 • Additives 124 • Antifreeze 125
• Preventive Maintenance 129 • Summary 130 • Terms to Know 130 • Review Questions 131
Chapter 5 Air-Conditioning System Operating Principles . . . . . . . . . . . 133
• Introduction 133 • Heat Transfer in the Refrigerant System 134 • Air Conditioning and Humidity 136
• The Relationship of Pressure and Vacuum in the Air-Conditioning System 138 • Air Conditioning 101 140
• Compressor 141 • Condenser 144 • Receiver-Drier Accumulator 144 • Metering Devices 146 • Evaporator 148
• Hoses and Lines 149 • Refrigerant 150 • Refrigerant R-134a (Hfc-134a) 153
• Refrigerant HFO-1234yf (R-1234yf) 155 • R-1234yf Refrigerant System Design 157
• Pressure versus Temperature Relationship 158 • Handling Refrigerant 160 • Air-Conditioning Circuit 161
• Summary 165 • Terms to Know 165 • Review Questions 165
Chapter 6 Refrigerant System Components . . . . . . . . . . . . . . . . . . . . . . 167
• Introduction 167 • The Refrigeration Cycle 167 • Compressor 170 • Hoses And Lines 172
• Discharge Line 175 • Condenser 176 • Receiver-Drier 180 • Liquid Line 183
• Thermostatic Expansion Valve 183 • H-Valve 188 • The Orifice Tube 190 • Evaporator 193
• Internal Heat Exchanger (IHX) 197 • Accumulator 198 • What Type System 199
• Summary 200 • Terms to Know 200 • Review Questions 200
v
Copyright 2017 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s).
Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
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Contents
Chapter 7 Refrigerant System Servicing and Testing . . . . . . . . . . . 203
• Introduction 203 • Performance Testing 203 • Refrigerant Analyzer 205
• Noncondensable Gas 207 • Moisture and Moisture Removal 209 • Prevention 212
• Evacuating the Refrigeration System (Moisture Removal) 212 • Moisture Removal at High Altitudes 214
• Mixed Refrigerant Types 215 • Hazardous Refrigerant 216 • Leak Detectors 216
• Leak Detection Using a Soap Solution 216 • Leak Detection Using Visible Dye 217
• Fluorescent Leak Detectors 217 • Electronic (Halogen) Leak Detectors 218 • Other Types 220
• Recovery/Recycling/Recharging Systems 221 • Record Keeping Requirements 225
• PDA Diagnostics 225 • Charging the System with Refrigerant 226 • Diagnosis 227
• Refrigeration Oil 232 • Summary 238 • Terms to Know 238 • Review Questions 239
Chapter 8 Diagnosis of the Refrigeration System . . . . . . . . . . . . . . 241
• Introduction 241 • System Diagnosis 241 • Temperature and Pressure Relationships of R-12 (CFC-12) 244
• Temperature and Pressure Relationships of R-134a (HFC-134a) 246
• Temperature and Pressure Relationships of R-1234yf (HFO-1234yf) 246
• Moisture Contamination 265 • Restriction Diagnosis 265 • Preventive Maintenance 267
• Advanced Diagnostic Tools 268 • High Pressure 272 • Connections 273 • Restrictions 273
• Contamination 274 • Summary 275 • Terms to Know 275 • Review Questions 275
Chapter 9 Compressors and Clutches . . . . . . . . . . . . . . . . . . . . . . . 278
• Introduction 278 • Function 278 • Design 279 • Clutch 281 • Types of Compressors 286
• Reciprocating (Piston-Type) Compressors 286 • Rotary Vane Compressors 290
• Scroll Compressors 291 • Scotch Yoke Compressors 293 • Variable Displacement Compressors 294
• Diagnosing Problems and Making Repairs 300 • Electric Motor–Driven Compressors 301
• Stretch to Fit Belts 303 • Summary 304 • Terms to Know 304 • Review Questions 304
Chapter 10 Case and Duct Systems . . . . . . . . . . . . . . . . . . . . . . . . . 306
• Introduction 306 • Air Intake 310 • Core Section 310 • Distribution Section 311
• Combined Case 311 • Air Delivery 312 • Dual-Zone Duct System 319 • Rear Heat/Cool System 320
• Evaporator Drain 323 • Odor Control 323 • Cabin Air Filters 325 • The Air Door Control System 329
• Control System Faults 333 • Visual Inspection 334 • Mode Door Adjustment 334 • Summary 335
• Terms to Know 335 • Review Questions 336
Chapter 11 System Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
• Introduction 338 • Manual Master Control 340 • Thermostat 344 • Pressure Cutoff Switch 347
• Factory-Installed Wiring 349 • Coolant Temperature Warning System 350
• Control Devices 352 • Vacuum System Diagrams 355 • Automatic Temperature Controls 356
• Electronic Temperature Control Systems 360 • Scan Tool 375 • Controller Area Network 379
• Heated and Climate Controlled Seating 385 • Summary 388 • Terms to Know 388 • Review Questions 388
Chapter 12 Retrofit and Future Trends (R-12 TO R-134a) . . . . . . . 392
• Introduction 392 • New Refrigerant Systems on the Horizon 393
• The Replacement Refrigerant of Choice 397 • Other Refrigerants 399 • Substitute Refrigerants 399
• The Do-It-Yourselfer 402 • Contaminated Refrigerant 403 • Purity Test 405
• Disposal of Contaminated Refrigerant 405 • Use of Alternate Refrigerants 405 • Retrofit Components 407
• System Flushing 413 • An Industry Study 413 • Summary 415 • Terms to Know 415 • Review Questions 415
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
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Copyright 2017 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s).
Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
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Preface
Thanks to the support the Today’s Technician™ series has received from those who teach
automotive technology. Cengage Learning, the leader in automotive-related textbooks, is able
to live up to its promise to provide new editions regularly. We have listened and responded to
our critics and our fans and present this new updated and revised sixth edition. By revising
our series regularly, we can and will respond to changes in the industry, changes in technology,
changes in the certification process, and to the ever-changing needs of those who teach
automotive technology.
The Today’s Technician™ series features textbooks that cover all mechanical and electrical
systems of automobiles and light trucks (while the heavy-duty trucks portion of the series does
the same for heavy-duty vehicles). Principally, the individual titles correspond to the main
areas of ASE (National Institute for Automotive Service Excellence) certification. Additional
titles include remedial skills and theories common to all of the certification areas and advanced
or specific subject areas that reflect the latest technological trends. Each text is divided into
two volumes: a Classroom Manual and a Shop Manual.
Unlike yesterday’s mechanic, the technician of today and for the future must know the
underlying theory of all automotive systems and be able to service and maintain those systems.
Dividing the material into two volumes provides the reader with the information needed
to begin a successful career as an automotive technician without interrupting the learning
process by mixing cognitive and performance learning objectives in one volume.
The design of Cengage’s Today’s Technician™ series was based on features that are known to
promote improved student learning. The design was further enhanced by a careful study of
survey results in which the respondents were asked to value particular features. Some of these
features can be found in other textbooks, whereas others are unique to this series.
Each Classroom Manual contains the principles of operation for each system and subsystem.
The Classroom Manual also contains discussions on design variations of key components used
by the different vehicle manufacturers. This volume is organized to build upon basic facts and
theories. The primary objective of this volume is to allow the reader to gain an understanding
of how each system and subsystem operates. This understanding is necessary to diagnose the
complex automobiles of today and tomorrow. Although the basics contained in the Classroom
Manual provide the knowledge needed for diagnostics, diagnostic procedures appear only in
the Shop Manual. An understanding of the basics is also a requirement for competence in the
skill areas covered in the Shop Manual.
A spiral-bound Shop Manual covers the “how-to’s.” This volume includes step-by-step
instructions for diagnostic and repair procedures. Photo Sequences are used to illustrate some
of the common service procedures. Other common procedures are listed and are accompanied
with fine-line drawings and photos that allow the reader to visualize and conceptualize the
finest details of the procedure. This volume also contains the reasons for performing the
procedures, as well as information on when that particular service is appropriate.
The two volumes are designed to be used together and are arranged in corresponding
chapters. Not only are the chapters in the volumes linked together, but the contents of the
chapters are also linked. This linking of content is evidenced by marginal callouts that refer the
reader to the chapter and page where the same topic is addressed in the other volume. This
feature is valuable to instructors. Without this feature, users of other two-volume textbooks
must search the index or table of contents to locate supporting information in the other
volume. This is not only cumbersome but also creates additional work for an instructor when
vii
Copyright 2017 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s).
Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
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Preface
planning the presentation of material and making reading assignments. This linking feature
is also valuable to students; with page references they also know exactly where to look for
supportive information.
The art is a vital part of each textbook. Both volumes contain clear and thoughtfully selected
illustrations, many of which are original drawings or photos specially prepared for inclusion in
this series.
The page layout used in the series is designed to include information that would otherwise
break up the flow of information presented to the reader. The main body of the text includes
all the “need-to-know” information and illustrations. In the wide side margins of each page
are many of the special features of the series: simple examples of concepts just introduced
in the text, explanations or definitions of terms that will not be defined in the glossary,
examples of common trade jargon used to describe a part or operation, and exceptions to the
norm explained in the text. Many textbooks attempt to include this type of information by
inserting it in the main body of text; this tends to interrupt the thought process and cannot be
pedagogically justified. By placing this information off to the side of the main text, the reader
can choose when to refer to it.
Jack Erjavec
Series Advisor
Highlights of this Edition—Classroom Manual
The Classroom Manual of this edition has been updated to include new technology used in
the automotive heating and air-conditioning systems of today’s vehicles while still retaining
information on systems used in older vehicles that are still in use. In addition, an emphasis has
been placed on updating images throughout the text with full-color photos. Charts, graphs,
and line drawings are now also in full color to be more visually appealing and improve the
content comprehension by the reader. Coverage of R-1234yf has been added throughout
the text. Chapter 2 covers the basic theories required to fully understand the operation and
diagnosis of the complete HVAC system. A chapter on electricity and electronic fundamentals
has been added covering the application and use of digital multimeters for those readers
that have a limited background in electrical applications. This is intended to improve their
understanding of electrical applications material covered in later chapters and prepare them
with the electrical knowledge needed to complete future job sheets. Chapter 4 covers the
automotive heating system and engine cooling system, including systems used on today’s
hybrid electric vehicles. The electronic thermostat used on some of today’s vehicles is
thoroughly explained along with the rationale behind its use.
The rest of the text is laid out in a logical order, beginning with basic air-conditioning
system operating principles and progressing to diagnosis of the refrigerant system. The
end-of-chapter questions in all chapters have been revised and updated. Updated coverage
on advanced electronics has been included, from the operation of electronic variable
compressors and electric motor–driven compressors to advanced sensors such as the airborne
pollutants sensor. Chapter 11 on HVAC system controls has been updated to include more
information on advanced climate control systems while still including a thorough description
of CAN system operation.
viii
Copyright 2017 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s).
Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
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