Automotive Heating and Air Conditioning, 9th edition James D. Halderman

Automotive Heating and Air Conditioning provides a complete, state-of-the-art source on automotive heating, ventilation and air conditioning systems, as well as the practical skills needed for success in the industry. The text focuses on the generic theory that underlies the operation, diagnosis and repair of the units and subassemblies found in the many makes and types of vehicles you’ll likely encounter in your career. Halderman uses helpful tips and visuals to bring concepts to life and guide you through the procedures you’ll use on the job. All the content is correlated to the latest NATEF tasks and ASE areas. This title is part of the Pearson Automotive Professional Technician Series, which provides full-color, media-integrated solutions covering all 8 areas of ASE certification. It also includes additional titles covering common courses. Peer reviewed for technical accuracy, the series and the titles in it represent the future of automotive texts.

Automotive Heating and Air Conditioning

Preface
Updates to the Ninth Edition
New to This Edition
Hallmark In-Text Features
Affordable Purchase Options for Students
Supplements
Technical and Content Reviewers
Photo Sequences
About the Author
Brief Contents
Contents
Chapter 1 Service Information, Work Orders, and Vehicle Identification
Learning Objectives
Key Terms
Owner’s Manuals
Content
Service Information
Purpose of Service Information
Factory Service Information
Aftermarket Service Information
Technical Service Bulletins
Recalls and Campaigns
Work Order
Service Advisor Documentation
Service Technician Documentation
Parts Documentation
Labor Time Documentation
Service Records
Purpose
Additional Information
From the Customer
Check the Vehicle Before Work is Started
Special Service Tools (SSTS)
Parts of a Vehicle
Left Side of the Vehicle—Right Side of the Vehicle
Front and Rear
Front-Wheel Drive Versus Rear-Wheel Drive
Vehicle Identification
Vehicle Safety Certification Label
VECI Label
Summary
Review Questions
Chapter Quiz
Chapter 2 Heating and Air-Conditioning Principles
Learning Objectives
Key Terms
HVAC
Purpose and Function
Principles Involved
Changes of State
Heat and Temperature
Sensible Heat
Latent Heat
Temperature, Volume, and Pressure of a Vapor
Heat Intensity
Rules of Heat Transfer
Humidity
Heating and Cooling Load
Heating Load
Cooling with Ice
Evaporative Cooling
Mechanical Cooling
Heat Movement
Conduction
Convection
Radiation
Air-Conditioning Process
Changing the State of the Refrigerant
Solid
Liquid
Gas
Purpose of an HVAC System
Control of Temperature
Control of Humidity
Cleanliness
Summary
Review Questions
Chapter Quiz
Chapter 3 The Refrigeration Cycle
Learning Objectives
Key Terms
The Refrigeration Cycle
Basic Principles
Refrigerant
How the A/C System Works
Refrigerant Movement
High- and Low-Side Identification
Expansion Devices
Expansion Cooling
Orifice Tube (OT) Systems
Thermal Expansion Valve (TXV) Systems
Low-Side Operation
Evaporators
Purpose
Condensers
Purpose and Function
Sub-Cool Condensers
Refrigerant Charge Level
Principles
Undercharged/Overcharged
Evaporator Icing Controls
Purpose
Thermistor
Pressure Switches
Summary
Review Questions
Chapter Quiz
Chapter 4 Air-Conditioning Compressors and Service
Learning Objectives
Key Terms
Compressors
Purpose and Function
Types of A/C Compressors
Piston Compressors
Piston Compressor Operation
Radial-Type Piston Compressors
Coaxial Swash-Plate Compressors
Coaxial Wobble-Plate Compressors
Variable Displacement Wobble-Plate Compressors
Vane Compressors
Construction
Operation
Scroll Compressors
Construction
Operation
Advantages
Disadvantages
Compressor Clutches
Purpose and Function
Parts and Operation
Damper Drives
Compressor Lubrication
Need for lubrication
How Oil is Circulated
Filters and Mufflers
Purpose and Function
Compressor Valves and Switches
Pressure Relief Valves
Switches on the Compressor
Compressor Control Switches
Compressor Speed Sensor
A/C Compressor Diagnosis and Service
Compressor Clutch Diagnosis
Compressor Clutch Replacement
Compressor Shaft Seal Replacement
Compressor Drive Belt Service
Belt Tensioner Service
Replacement Compressors
Identify the Unit
Oil Charge
Summary
Review Questions
Chapter Quiz
Chapter 5 Refrigerants and Refrigerant Oils
Learning Objectives
Key Terms
Refrigerants
Definition and Types
Refrigerant Containers
Legislation
Clean Air Act
Section 609
Kyoto Protocol
Environmental Issues
Ozone Layer
Ozone Depletion
Global Warming and Greenhouse Gases
HFO-1234yf
Description
Unique Fittings
Mandated
Flammability
R-1234yf Concerns
R1234yf Safety Precautions
Carbon Dioxide as a Refrigerant
Definition
CO2 as a Refrigerant
Alternate Refrigerants
Snap Program
Counterfeit and Bootleg Refrigerants
Non-Condensable Gas
Definition
Checking for NCG
Refrigerant Safety
Potential Hazards
Precautions
Refrigerant Oils
Purpose and Function
Types of Refrigerant Oils
R-1234yf Refrigerant Oil
Viscosity of Refrigerant Oils
Hygroscopic
Oil Flow in the System
Summary
Review Questions
Chapter Quiz
Chapter 6 A/C System Components, Operation, and Service
Learning Objectives
Key Terms
Compressors
Purpose and Function
Condensers
Purpose and Function
Condenser Construction
Thermal Expansion Valves
Purpose and Function
Advantages
Disadvantages
Construction and Operation
Internally and Externally Balanced TXVs
Types of TXVs
H-Blocks
Orifice Tube Systems
Terminology
Advantages
Disadvantages
Construction and Operation
Orifice Tube Sizes
Orifice Tube Location
Variable Orifice Valves (VOVs)
Electronic Orifice Tube
Evaporators
Purpose and Function
Construction
Receiver–Driers and Accumulators
Purpose and Function
Desiccant
Accumulators
Receiver–Drier
Sight Glass
Lines and Hoses
Purpose and Function
Hose Construction
Metal Lines
Hose Sizes
Connections
O-Rings
Electrical Switches and Evaporator Temperature Controls
Control Switches
Thermostatic Cycling Switch
Pressure Cycling Switches
Low-Pressure Switch
Thermistors and Transducers
Rear A/C Systems
Parts and Operation
Component Replacement Procedures
Fitting Repair
Line Replacement
A/C Component Replacement
Orifice Tube Replacement
TXV Replacement
Summary
Review Questions
Chapter Quiz
Chapter 7 Air Management System
Learning Objectives
Key Terms
Terminology
Air Management
Heat
Air Conditioning
Ventilation
Defogging or Defrosting the Inside of the Windshield
HVAC Control Head
Airflow Control
Operation
Types of Doors
Air Temperature Control
Temperature Control Using Airflow
Temperature Control Using a Variable Compressor
Air Filtration
Terminology
Housing and Ducts
Construction
Plenum and Control Doors
Air Inlet Control Door
Temperature-Blend Door
Air Distribution and Outlets
Dual-Zone Air Distribution
Nonelectrical HVAC Controls
Cable-Operated Systems
Vacuum-Operated Systems
Electronic HVAC Controls
Overview
Two-Wire Actuators
Three-Wire Actuators
Five-Wire Actuators
Actuator Calibration Procedures
Blower Motor
Purpose and Function
Parts and Operation
Variable Speed Control
Blower Motor Diagnosis
Summary
Review Questions
Chapter Quiz
Chapter 8 Antifreeze and Coolant
Learning Objectives
Key Terms
Coolant Fundamentals
Definition
Purpose of Coolant
Freezing/Boiling Temperatures
Coolant Composition
Types of Coolant
Inorganic Acid Technology
Organic Acid Technology
Hybrid Organic Acid Technology
Phosphate Hybrid Organic Acid Technology
Universal Coolant
Water
Introduction
Properties
Coolant Freezing/Boiling Temperatures
Freezing Point
Boiling Point
Coolant Testing
Hydrometer Testing
Refractometer
PH
Galvanic Activity
Electrolysis
Testing for Galvanic Activity and Electrolysis
Test Strip Testing
Coolant Replacement Issues
Intervals
Passivation
Recycling Coolant
Summary
Review Questions
Chapter Quiz
Chapter 9 Cooling System Operation and Diagnosis
Learning Objectives
Key Terms
Cooling System
Purpose and Function
Low-Temperature Engine Problems
High-Temperature Engine Problems
Cooling System Operation
Purpose and Function
Cooling System Operation
Thermostats
Purpose and Function
Thermostat Operation
Thermostat Testing
Thermostat Replacement
Radiators
Types
How Radiators Work
Pressure Caps
Operation
Functions
Metric Radiator Caps
Coolant Recovery Systems
Purpose and Function
Surge Tank
Water Pumps
Operation
Water Pump Service
Coolant Flow in the Engine
Types of Systems
Coolant Flow and Head Gasket Design
Cooling Fans
Electronically Controlled Cooling Fan
Thermostatic Fans
Heater Cores
Purpose and Function
Heater Problem Diagnosis
Cooling System Testing
Visual Inspection
Pressure Testing
Coolant Dye Leak Testing
Coolant Temperature Warning Light
Purpose and Function
Precautions
Common Causes of Overheating
Cooling System Inspection
Coolant Level
Accessory Drive Belt Tension
Cooling System Service
Flushing Coolant
Coolant Exchange Machine
Hose Inspection
Disposing of Used Coolant
Cleaning the Radiator Exterior
Hose Clamps
Summary
Review Questions
Chapter Quiz
Chapter 10 Heating System Operation and Diagnosis
Learning Objectives
Key Terms
Heating System
Purpose and Function
Heater Core
Operation
Flow Restrictors
Dual Heating Systems
Heater Diagnosis
Visual Inspection
Scan Tool Diagnosis
Electrically Heated Seats
Parts and Operation
Diagnosis and Service
Heated and Cooled Seats
Parts and Operation
Diagnosis and Service
Heated Steering Wheel
Parts Involved
Operation
Diagnosis and Service
Summary
Review Questions
Chapter Quiz
Chapter 11 HVAC Electricity and Electronics
Learning Objectives
Key Terms
Introduction
Electricity
Background
Definition
Positive and Negative Charges
Magnets and Electrical Charge
Electron Orbits
Conductors
Insulators
Semiconductors
How Electrons Move Through a Conductor
Current Flow
Conventional Theory Versus Electron Theory
Units of Electricity
Ampere
Volts
Ohms
Electrical Circuits
Definition
Parts of a Complete Circuit
Electrical Schematics
Terminology
Circuit Information
Wire Size
Types of Circuit Faults
Open Circuits
Short-to-Voltage
Short-to-Ground
High Resistance
Fused Jumper Wire
Purpose and Function
Test Light
Non-Powered Test Light
Uses of a 12-Volt Test Light
Digital Meters
Terminology
Measuring Voltage
Measuring Resistance
Measuring Amperes
Inductive Ammeters
Operation
AC/DC Clamp-On Digital Multimeters
Think of Money
Terminals and Connectors
Terminology
Servicing Terminals
Wire Repair
Soldering
Soldering Procedure
Crimping Terminals
Heat Shrink Tubing
Crimp-and-Seal Connectors
Relays
Definition
Terminal Identification
Networks
Need for Network
Modules and Nodes
Types of Communication
Network Classifications
Controller Area Network
Summary
Review Questions
Chapter Quiz
Chapter 12 Automatic Temperature Control Systems
Learning Objectives
Key Terms
Automatic Temperature Control System
Purpose and Function
Operation
Sensors
Purpose and Function
Outside Air Temperature Sensor
In-Vehicle Temperature Sensor
Discharge Air Temperature Sensor
Evaporator Temperature Sensor
Sun Load Sensor
Infrared Sensors
Compressor Speed Sensor
Engine Coolant Temperature Sensor
Pressure Transducers
Air Quality Sensors
Relative Humidity Sensor
GPS Sensor
Airflow Control
Need for Airflow Control
Airflow Control Doors
Controlling Airflow
Actuators
Purpose and Function
Types of Actuators
Electric Actuator Motors
Dual-Zone Systems
Automatic HVAC Controls
Operation
Compressor Controls
Compressor Control Module
Controlling Air Temperature
Air Filtration
Purpose and Function
Types of Cabin Filters
Automatic Climatic Control Diagnosis
Diagnostic Procedure
Scan Tool Bidirectional Control
Scan Tool Data
Summary
Review Questions
Chapter Quiz
Chapter 13 EV and HEV HVAC System
Learning Objectives
Key Terms
Hev Ice Cooling System
Engine Cooling
Basic Operation
Water Pump
Thermostat
HEV Cabin Heating Systems
Principles
Parts and Operation
Heating Systems
Electric Engine Water Pump
Heat Mode
Modes of Operation
Failure Mode
Auxiliary Water Pump Diagnosis
Coolant Heat Storage System
Purpose
Parts and Operation
PTC Heaters
Operation
HEV Cabin Cooling
Basic Operation
Airflow
Defrost
A/C MODE
HEV A/C Components
Compressors
Compressor Drives
Compressor Oil
Condensers
Subcooling Condensers
Expansion Devices
Evaporators
Thermal Storage During Idle Stop
Unique Hybrid and Electric Vehicle Air-Conditioning Service
EV Heating
Emphasis is on Range
Electrical Resistance Heating
PTC Heaters
Heat Pump
Purpose and Function
Parts and Operation
Liquid Cooled Condenser (LCC)
Summary
Review Questions
Chapter Quiz
Chapter 14 A/C Inspection, Performance Testing, and Leak Detection
Learning Objectives
Key Terms
Inspection
Verify System Is Functioning as Designed
A/C Compressor Operation
Compressor Drive Belt
A/C Vent Temperature Readings
HVAC System Inspection
Visual Inspection
Cabin Filter
A/C and Heater Duct Inspection
Blend Door Operation
Heater Hose Inspection
Condenser Inspection
A/C Service Ports
Service Caps
Connecting the Pressure Gauges
Gauge Pressure Versus Absolute Pressure
A/C Performance Test
Procedure
System Test Results
Common Issues with A/C Systems
Temperature and Pressure Measurements
Temperature Differences Across Components
Leak Detection
Purpose
Electronic Leak Detection
Dye Leak Detection
Soapy Water
Using Dye
Summary
Review Questions
Chapter Quiz
Chapter 15 Refrigerant Recovery, Recycling, and Recharging
Learning Objectives
Key Terms
Safety First
Suggested Guidelines
SAE J Standards
Purpose
Commonly Cited Standards
Refrigerant Identification
Cross Contamination
Refrigerant Identifier
Types of Identifiers
Steps to Identify the Refrigerant
Disposing of Unknown Refrigerant
Non-Condensable Gases (NCG)
Moisture in the Refrigerant System
Sealant Contamination
A/C Servicing
Steps Involved
Refrigerant Recovery
Equipment Needed
Engine Pre-Heat Procedure
Recovery Operation
Storage Container Certification
Steps to Recover Refrigerant
Recycling Refrigerant
Recycling Equipment
Filter Maintenance
Quality Standards
Recycle Only Units
Procedure for Recycling
Air Contamination Checks
Test Results
Flushing an A/C System
Purpose
Cautions and Precautions
Replacing Components
General Guidelines
O-Rings
Tightening Connections
Service Fittings and Caps
Schrader Valves
Inline Filter
Purpose and Function
Installing an in-Line Filter
Refrigerant Oil
Adding Oil
Evacuating the System
Purpose of Evacuating the System
Micron Rating
Vacuum Pump Service
Evacuation Time
Evacuation Procedure Using a Gauge Set and Portable Pump
Evacuation Procedure Using an Rrr Machine
Recharging the System
Procedure
Unit Conversion
Recommended Charging Procedure
Recharging with an RRR Machine
R-1234yf Evacuate and Recharge
Sealants and Stop Leaks
Purpose
Sealant Concerns
Types
Summary
Review Questions
Chapter Quiz
Chapter 16 A/C System Diagnosis and Repair
Learning Objectives
Key Terms
Diagnostic Procedure
Strategy-Based Diagnostics
Common Issues with A/C Systems
Verify Customer Concern
Understand the Exact Fault
Visual Inspection
Underhood Checks
In-Vehicle Checks
Engine Running Checks
Check DTCs
Check Under Body or Chassis
Check TSBs
Fourth Step
Perform A/C Performance Test
Procedure
System Test Results
Root Cause
Temperature and Pressure Measurements
Temperature Differences Across Components
Addressing System Odors
Source of Odors
Noise Issues
Common Causes
Repair the System
Purpose
Typical Repairs
Verify the Repair
Retrofitting
Purpose
Epa Retrofit Requirements
Refrigerant Choice for Retrofit
Recommended Guidelines
Retrofit Kits
Retrofit Procedure
Summary
Review Questions
Chapter Quiz
Chapter 17 EPA Section 609 Certification
Learning Objectives
Key Terms
609 Certification Test
Purpose
Climate Change (Global Warming)
609 Training Requirement
Essentials Involved
Section 609 Certification Exam
Open Book
Certification Exam Topics
Certified Section 609 Equipment
Needed to Work on Motor Vehicle A/C units
Section 609 Service Practices
Best Practices
Refrigerant Tanks
Identify Refrigerants
R-1234yf Systems
Issues and Concerns
Vehicle Label
Fittings
Refrigerant Recovery
Engine Pre-Heat Procedure
Recovery Procedure
Recovery-Only Equipment
A/C System Evacuation
Leaks Must be Repaired
Leak Check Procedure Using an RRR Machine
Check Oil Removed
Safety Precautions and Warnings
Charging
Proper Charge Needed
Leak Detection
Recordkeeping
RRR Machine Maintenance
Disposal of Refrigerants
Benefits of a Section 609 Certification
Sample 609 Test with Answers
Answers:
Summary
Review Questions
Chapter Quiz
Appendix 1 Sample A7 ASE Certification-Type Test with Answers
Answers
Appendix 2 ASE Education Foundation – A7 Correlation Chart
Glossary
Index
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
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T
U
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W
X