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AUTOMOTIVE

HEATING

AND AIR

CONDITIONING

5 '

AUTOMOTIVE

HEATING AND AIR

CONDITIONING

SEVENTH EDITION

James D. Halderman

Tom Birch

T H 'f ViR^;

PEARSON

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Library of Congress Cataloging-in-Publication Data

Halderman, James D.

(Automotive heating and air conditioning]

Automotive heating and air conditioning/James Halderman, Tom Birch.-Seventh edition,

pages cm

Rev. ed. of: Automotive heating and air conditioning/Tom Birch. 2012.

Includes index.

ISBN 978-0-13-351499.5 (alk. paper)-ISBN 0-'Ĩ3-351499-4 (alk. paper) 1. Automobiles￾Heating and ventilation. 2. Automobiles-Air conditioning. I. Birch, Thomas w. CThomas

Wesley). II. Birch, Thomas w. CThomas Wesley). Automotive heating

and air conditioning. III. Title.

TL271.B57 2015

629.2'772-dc23

2014012799

10 987654321

PEARSON ISBN 10: 0-13-351499-4

ISBN 13: 978-0-13-351499-5

PREFACE

PR O FESSIO NAL TE C H N IC IA N SERIES Part of the

Pearson Automotive Professional Technician Series, the

seventh edition of Automotive Heating and Air Conditioning

represents the future of automotive textbooks. The series is

a full-color, media-integrated solution for today’s students

and instructors. The series includes textbooks that cover all

eight areas of ASE certification, plus additional titles covering

common courses. The series is peer reviewed for technical

accuracy.

U PDATES TO THE SEVENTH EDITIO N Based on

comments and suggestions from instructors throughout the

country, the following changes have been made to the new

seventh edition:

■ New fuil-color design makes it easier to read.

■ All new full-coior line drawings and photos throughout to

help bring the subject to life.

■ Many new or extensively updated chapters on heating

and air-conditioning systems.

• A new chapter covering A/C compressors and

compressor service all in one chapter (Chapter 5).

■ A new chapter covering all aspects of automatic

temperature control systems added (Chapter 12).

■ Another new chapter on hybrid electric vehicle heating

and A/C systems (Chapter 13) added.

■ All chapters updated with the latest technology.

■ New questions at the end of the chapters (both review

questions and chapter quizzes).

■ More concisely written to make teaching and learning

easier.

■ Two new appendixes. Sample ASE certification test

(Appendix 1) and NATEF correlation chart (Appendix 2).

■ Unlike other textbooks, this book is written so that the

theory, construction, diagnosis, and service of a particu￾lar component or system are presented in one location.

There is no need to search the entire book for other refer￾ences to the same topic.

ASE AN D NATEF CO RRELATED NATEF certified

programs need to demonstrate that they use course material

that covers NATEF and ASE tasks. All Professional Technician

textbooks have been correlated to the appropriate ASE and

NATEF task lists. These correlations can be found in Appendix 2.

A C O M P LE TE IN S T R U C T O R A N D S T U D E N T

SUPPLEM ENTS PACKAGE All Professional Technician

textbooks are accompanied by a full set of instructor and

student supplements. Please see page vi for a detailed list of

supplements.

A FO CUS ON D IA G N O S IS A N D P R O B L E M

SOLVING The Professional Technician Series has been

developed to satisfy the need for a greater emphasis on problem

diagnosis. Automotive instructors and service managers agree

that students and beginning technicians need more training

in diagnostic procedures and skill development. To meet this

need and demonstrate how real-world problems are solved,

“ Real World Fix” features are included throughout and highlight

how real-life problems are diagnosed and repaired.

The following pages highlight the unique core features

that set the Professional Technician Series book apart from

other automotive textbooks.

PREFACE i i i

IN-TEXT FEATURES

" n

chapter 1

INFORMATION, TOOLS,

AND SAFETY

SAFETY TIP

Shop Cloth Disposal

Always dispose of oily shop cloths in an enclosed

container to prevent a fire. • SEE FIGURE 1-69.

Whenever oily cloths are thrown together on the floor

or workbench, a chemical reaction can occur, which

can ignite the cloth even without an open flame. This

process of ignition without an open flame is called

spontaneous combustion.

SAFETY TIPS alert students to possible hazards on the

job and how to avoid them.

A

REAL W ORLD FIX

LEARNING OBJECTIVES AND KEY TERMS appear at

the beginning of each chapter to help students and instructors

focus on the most important material in each chapter. The

chapter objectives are based on specific ASE and NATEF tasks.

Cabin Filter Fault

The owner of a 2008 Ford Escape complained that

the air-conditioning system was not cooling tfie Inside

of the vehicle and there seemed to be no airflow from

the dash vents yet the blower motor could be heard

njnning. A quick visual inspection of the cabin air with

access under the hood showed that the cabin filter

was almost completely blocked with paper, leaves,

and debris. The vehicle had almost 80,000 miles on the

odometer and the way it looked, the air filter had never

been replaced. Most vehicle manufacturers recom￾mend replacement of the cabin air filter about every

three years or every 36,000 miles. Replacing the cabin

air filter restored proper operation of the A/C system.

TECH TIP

It Just Takes a Second

Whenever removing any automotive component, it is

wise to screw the bolts back into the holes a couple

of threads by hand. This ensures that the right bolt

will be used in its original location when the compo￾nent or part is put back on the vehicle.

TECH TIP S feature real-world advice and “tricks of the

trade” from ASE-certified master technicians.

REAL WORLD FIXES present students with actual auto￾motive scenarios and show how these common (and some￾times uncommon) problems were diagnosed and repaired.

? FREQUENTLY ASKED QUESTION

How Many Types of Screw Heads Are Used in

Automotive Applications?

There are many, including Torx, hex (also called

Allen), plus many others used in custom vans and

motor homes. • SEE FIGURE 1-9.

FREQUENTLY ASKED QUESTIONS are based on the

author’s own experience and provide answers to many of the

most common questions asked by students and beginning ser￾vice technicians.

iv IN-TEXT FEATURES

NOTE: Most of these “locking nuts'* are grouped togeth'

er and are commonty referred to as prevailing torque

nuts. This means that the nut will hold its tightness or

torque and not loosen with movement or vibration.

NO TES provide students with additional technical

information to give ữìem a greater understanding of a specific

task or procedure.

CAUTION: Never use hardware store (nongraded) boKs,

studs, or nuts on any vehicle steering, suspension, or

brake component. Ahivays use the exact size and grade

of harttware that is specified and used by the vehicle

manufacturer.

C A U TIO N S alert students about potential damage to

the vehicle that can occur during a specific task or service

procedure.

Do not use incandescent trouble lights around

gasoline or other flammable liquids. The liquids

can cause the bulb to break and the hot filament

can ignite the flammable liquid, which can cause

personal injury or even death.

THE SU M M AR Y, REVIEW QUESTIONS, AND CHAPTER

QUIZ at the end of each chapter help students review the

W A R N IN G S alert students to potential dangers to material presented in the chapter and test themselves to see

themselves during a specific task or service procedure. how much they've learned.

m

lỉẩ 3 ■

5 'm n6*— “

STEP-BY-STEP photo sequences show

in detail the steps involved in performing a

specific task or service procedure.

IN-TEXT FEATURES V

SUPPLEM ENTS

“ 1

R E S O U R C E S IN P R IN T A N D O N LIN E

Automotive Heating and Air Conditioning

NAMEOFSUPPL£MENT PRINT AUDIENCE

Instructor

Resource Manual

013351f>3fi?

✓ Instructors NEW! Tiie Ultimate teaching aid; Chapter

summaries, key temis, chapter learning

objectives, lecture resources, discuss/

demonstrate classroom activities,

and answers to the in text review and

quiz questions.

TestGen

0133515389

✓ Instructors Test generation software and test b ^ k

for the text.

Presentation

0133515397

✓ Instructors Slides include chapter learning objectives,

lecture outline of the test, and graphics

from the book.

Image Bank

0133515079

✓ Instructors Ail of the images and graphs from the

textbook to create customized lecture

slides.

HATEF Correlated Task

Sheets - fm- instructors

0133515087

✓ Insfructors Downloadable NATEF task sheets for

easy customization and development

of unique task sheets.

NATEF Task

Sheets - For

Students

0133515354

✓ Students Study activity manual that correlates NATEF

Automobile Standards to chapters and

pages numbers in the text. Available to

students at a discounted price when

packaged with the text.

CourseSmart eText

0133515109

✓ Students atternative to purchasing the print

textbook, students can subscribe to the

same content online and save up to 50%

off the suggested list price of the print text.

VisK www.coursesmart.coiT)

All online reso urce can be downloaded from the Instructor's Resource C enter w

V ' SUPPLEMENTS

ACKNOWLEDGMENTS

A large number of people and organizations have cooperated in

providing the reference material and technical information used

in this text. The authors wish to express sincere thanks to the

following organizations for their special contributions:

American Honda

Bill Steen, Yuba College

David Brainerd, Santa Barbara City College

Fluke Corporation

Four Seasons

Frank Allison, International Mobile Air Conditioning

Association (IMACA), Executive Director

Frederick Peacock, Purdue University

General Motors Corporation

Harold Beck, Yuba City

James Johnson, Four Seasons

Lorie Homolish Apollo America Corporation

Martin Duvic, Louisiana Technical College

Mastercool

Modine Manufacturing

Nartron Corp. /Smart Power Products

Neutronics Inc.

Patrick L O’Conner, Fedco Automotive Components

Paul De Guiseppi, Mobile Air Conditioning Society

(MACS)

Raytek Corp.

Red Dot Corp.

Robert Bassett. The Gates Rubber Company

Robinaire Division, SPX Corporation

Sanden International (USA)

Santech Industries

Simon Oulouhojian, Past President Mobile

Air Conditioning Society (MACS)

Society of Automotive Engineers (SAE)

stant Manufacturing

System Guard

Tom Broxholm, Skyline College

Tony Jewel, Reedley College

Toyota Motor Sales, USA

TECHNICAL AND CONTENT REVIEWERS Thefoiiowing

people reviewed the manuscript before production and

checked it for technical accuracy and clarity of presentation.

Their suggestions and recommendations were included in

the final draft of the manuscript. Their input helped make this

textbook clear and technically accurate while maintaining the

easy-to-read style that has made other books from the same

authors so popular.

Tom Broxholm

Skyline College

Ron Chappell

Santa Fe Community College

Curtis Cline

Wharton County Junior College

Matt Dixon

Southern Illinois University

Kenneth p. Dytrt

Pennsylvania College of Technology

Curtis Happe

Richland Community College

Chris Holley

Penn College Professor

Paul Hye

Brookdale Community College

Dr. David Gilbert

Southern Illinois University

Richard Kneger

Michigan Institute of Technology

Russell A. Leonard

Ferris state University

William Milam

Eastfield College

Justin Morgan

Sinclair Community College

Greg Pfahl

Miami-Jacobs Career College

Steve Polley

Pittsburg State University

Jeff Rehkopf

Florida State College

Michael Reimer

South Plains College

Scott Russell

Blue Ridge Community College

Eugene Talley

Southern Illinois University

Chuck Taylor

Sinclair Community College

Omar Trinidad

Southern Illinois University

Ken Welch

Saddleback College

Special thanks to instructional designer Alexis I. Skriloff

James.

ACKNOWLEDGMENTS vii

PHOTO SEQUENCES The authors wish to thank Chuck of the manuscript before publication and to Richard Reaves for

Taylor of Sinclair Community College in Dayton Ohio plus Greg 3" of his help. Most of all, we wish to thank Michelle HaWerman

Pfahl and James (Mike) Watson who helped with many of the assistance In all phases of manuscript preparation.

photos. A special thanks to Randal Sedwick, Dick Krieger, Jeff James D. Halderman

Rehkopf, and EugeneTalleyfortheirdetailed and thorough review Tom Birch

viii ACKNOWLEDGMENTS

ABOUT THE AUTHORS

JAM ES D. HALDERMAN Jim Halderman brings a world of

experience, knowledge, and talent to his work. His automotive

service experience includes working as a flat-rate technician, a

business owner, and a professor of automotive technology at a

leading U.S. community college for more than 20 years.

He has a Bachelor of Science degree from Ohio Northern

University and a Master’s degree in Education from Miami

University in Oxford, Ohio. Jim also holds a U.S. patent for

an electronic transmission control device. He is an ASE￾certified Master Automotive Technician and Advanced Engine

Performance (L1) ASE certified. Jim is the author of many

automotive textbooks, all published by Pearson. Jim has

presented numerous technical seminars to national audiences,

including the California Automotive Teachers (CAT) and the

Illinois College Automotive Instructor Association (ICAIA). He is

also a member and presenter at the North American Council of

Automotive Teachers (NACAT). Jim was also named Regional

Teacher of the Year by General Motors Corporation and an

outstanding alumnus of Ohio Northern University. Jim and his

wife, Michelle, live in Dayton, Ohio. They have two children.

You can reach Jim at:

[email protected]

TOM BIRCH Tom Birch started his automotive service career

working as a service technician at a Ford dealership. Then,

while in the army, he was a wheel vehicle mechanic and worked

as a technician on army vehicles when stationed in Europe. He

earned his Bachelor’s and Master’s degrees from Chico state

College, now California State University, Chico, and taught in

the California school system before going to Yuba College in

Northern California. Tom is past president and board member

of the California Automotive Teachers (CAT), plus a member

and winner of the MVP award of the North American Council

of Automotive Teachers (NACAT). He is also a member of the

Mobile Air Conditioning Society (MACS), Automotive Service

Council California (ASC-CA), and the Society of Automotive

Engineers (SAE). Tom is the author of many automotive text￾books, all published by Pearson.

ABOUT THE AUTHORS ỈX

BRIEF CONTENTS

c h a p te r 1 Service Inform ation, Tools, and Safety 1

c h a p te r 2 Environm ental and Hazardous M aterials 39

c h a p te r 3 Heating and A ir-C onditioning Principles 52

ch a p te r 4 The Refrigeration C ycle 63

c h a p te r 5 Air-C onditioning C om pressors and Service 75

c h a p te r 6 Refrigerants and Refrigerant O ils 93

c h a p te r 7 A /C System Components, O peration, and Service 103

c h a p te r 8 A ir M anagem ent System 125

c h a p te r 9 HVAC E lectricity and E lectronics 138

c h a p te r 10 C ooling System O peration and Diagnosis 162

c h a p te r 11 Heating System O peration and Diagnosis 186

c h a p te r 12 A utom atic Tem perature Control System s 196

c h a p te r 13 Hybrid and Electric Vehicle HVAC System s 211

c h a p te r 14 Refrigerant Recovery, Recycling, and R echarging 223

c h a p te r 15 A /C System Diagnosis and R epair 244

a p p e n d ix 1 Sam ple A7 ASE C ertification-T ype Test w ith Answ ers 261

a p p e n d ix 2 2013 NATEF Correlation Chart 266

G lossary 269

Index 274

n

X BRIEF CONTENTS

CONTENTS

chapter 1

SERVICE INFORMATION, TOOLS,

AND SAFETY 1

• Learning Objectives 1

• Key Terms 1

■ Vehicle Identification 2

■ Service Information 3

■ Threaded Fasteners 4

■ Hand Tools 8

■ Basic Hand Tool List 18

■ Tool Sets and Accessories 20

■ Electrical Hand Tools 20

■ Hand Tool Maintenance 21

■ Trouble Lights 21

• Air and Electrically operated Tools 22

■ Personal Protective Equipment 24

■ Safety Precautions 25

• Vehicle Protection 26

■ Safety Lifting (Hoisting) a Vehicle 26

■ Jacks and Safety Stands 28

■ Drive-On Ramps 28

- Electrical Cord Safety 28

■ Jump Starting and Battery Safety 29

■ Fire Extinguishers 30

• Fire Blankets 31

■ First Aid and Eye Wash Stations 31

• Hybrid Electric Vehicle Safety Issues 33

H o is t in g t h e V e h ic l e P h o t o S e q u e n c e 35

S u m m a r y 37

R e v ie w Q u e s t io n s 37

C h a p t e r Q u iz 37

chapter 2

ENVIRONMENTAL AND

HAZARDOUS MATERIALS 39

Learning Objectives 39

Key Terms 39

■ Hazardous Waste 40

• Federal and State Laws 40

• Asbestos Hazards 42

• Used Brake Fluid 43

■ Used Oil 43

■ Solvents 44

■ Coolant Disposal 45

“ Lead-Acid Battery Waste 46

• Fuel Safety and storage 47

■ Airbag Handling 47

■ Used Tire Disposal 48

■ Air-Conditioning Refrigerant Oil Disposal 48

S u m m a r y 50

R e v ie w Q u e s t io n s 5 0

C h a p t e r Q u iz 51

chapter 3

HEATING AND AIR-CONDITIONING

PRINCIPLES 52

Learning Objectives 52

Key Terms 52

■ Introduction 53

■ Heating and Cooling Load 56

■ Heat Movement 58

■ Air-conditioning Process 59

■ Purpose of an HVAC System 60

S u m m a r y 61

R e v ie w Q u e s t io n s 61

C h a p t e r Q u iz 6 2

chapter 4

THE REFRIGERATION

CYCLE 63

Learning Objectives 63

Key Terms 63

■ Basic Principles 64

• Evaporators 67

■ Thermal Expansion Valves 68

■ Orifice Tube Systems 69

• Condensers 70

■ Refrigerant Charge Level 71

■ Evaporator Icing Controls 71

S u m m a r y 73

R e v ie w Q u e s t io n s 73

C h a p t e r Q u iz 73

CONTENTS X '

chapter 5

AIR-CONDITIONING

COMPRESSORS AND

SERVICE 75

■ Learning Objectives 75

■ Key Terms 75

■ Compressors 76

■ Piston Compressors 76

■ Vane Compressors 79

• Scroll Compressors 80

■ Compressor Clutches 81

■ Compressor Lubrication 84

- Filters and Mufflers 84

■ Compressor Valves and Switches 84

■ A/C Compressor Diagnosis and Service 85

• Replacement Compressors 89

S u m m a r y 91

R e v ie w Q u e s t io n s 91

C h a p t e r Q u iz 91

chapter 6

REFRIGERANTS AND

REFRIGERANT OILS 93

■ Learning Objectives 93

• Key Terms 93

■ Refrigerants 94

■ Environmental Issues 94

■ Legislation 96

■ Alternate Refrigerants 97

• Future Refrigerants 98

■ Refrigerant Safety Precautions 99

■ Refrigerant Oils 100

S u m m a r y 10 2

R e v ie w Q u e s t io n s 1 0 2

C h a p t e r Q u iz 1 0 2

chapter 7

A/C SYSTEM COMPONENTS,

OPERATION, AND SERVICE 103

Learning Objectives 103

Key Terms 103

■ Background 104

■ Compressors 104

• Condensers 104

■ Thermal Expansion Valves 107

■ Orifice Tube Systems 108

■ Evaporators 110

■ Receiver-Driers and Accumulators 112

■ Lines and Hoses 114

■ ElectricaJ Switches and Evaporator Temperature Controls 117

■ Rear A/C Systems 120

■ Component replacement Procedures 120

S u m m a r y 1 2 3

R e v ie w Q u e s tio n s 1 2 3

C h a p te r Q u iz 1 2 3

chapter 8

AIR MANAGEMENT SYSTEM

■ Learning Objectives 125

■ Key Terms 125

■ Introduction 126

■ Airflow Control 128

■ Air Temperature Control 128

■ Air Filtration 129

• Cases and Ducts 130

■ Plenum and Control doors 130

■ Nonelectrical HVAC Controls 132

- Electronic HVAC Controls 132

■ Blower Motor Control 136

S u m m a r y 1 37

R e v ie w Q u e s t io n s 1 37

C h a p t e r Q u iz 1 37

chapter 9

HVAC ELECTRICITY AND

ELECTRONICS 138

Learning Objectives 138

Key Terms 138

■ Introduction 139

■ Electricity 139

• How Electrons Move Through a Conductor 141

• Units of Electricity 141

■ Electrical Circuits 143

■ Electrical Schematics 143

■ Types of Circuit Faults 144

• Fused Jumper Wire 146

• Test Light 147

• Digital Meters 148

125

xii CONTENTS