Refrigerant Identifiers
Recovering the Refrigerant
Evacuating the System
Charging the AC System
Oil for the AC System
Chapter 6: Repairing the AC System
Repairing and Replacing Parts
Component Flushing
Cleaning the Evaporator Core
Metering Devices
Dryer Devices
Compressor
Condenser
Evaporator Core
Retrofitting R12 Systems to R134a
Chapter 7: Electrical Operation and Repair of the HVAC System
Electrically Controlled Components
Diagnosing Electrical Problems
Electrical Testing
Hybrid and Electric Vehicle Testing
Overview
Heating System Operation
Diagnosis
Repair Procedures
ABOUT THE AUTHOR
Jerry Clemons holds an AAS in Automotive Technology from Southern Illinois University as well as a BS in Technical Education from Western Kentucky University. Jerry also earned an MS degree in Safety, Security, and Emergency Management from Eastern Kentucky University. He has been employed at Elizabethtown Community and Technical College since 1999, where he is a professor and program coordinator for the Automotive and Diesel Technology programs. He is certified by ASE as a master automotive technician as well as a master truck technician. Jerry is an active member of the Mobile Air Conditioning Society (MACS) as well as the North American Council of Automotive Teachers (NACAT).
ACKNOWLEDGMENTS
Before getting started, I would like to give some recognition to some great people who supported me through this project. First of all, I would like to thank my family for their patience and understanding while I worked on this book during some late nights, early mornings, and many weekends and holidays. My son, Austin Clemons, was especially supportive in sharing his expertise with the photography and setting up scenes for the photographs. I would also like to thank Jim Halderman for his expert advice and guidance as I worked through this project. Jim has been an automotive author for many years and his support was very valuable as I completed this book.
I also want to acknowledge the following individuals at Elizabethtown Community and Technical College: Mike Hazzard, dean of the Technical Division; Brent Doty, program coordinator of the Computer Aided Drafting and Design (CADD) program; Thomas Frost, CADD student; Calista Reid, CADD student; and John Chism, automotive professor.
There were also several local businesses that supported this project in various ways and deserve recognition: Swope’s Cars of Yesteryear Museum in Elizabethtown, Kentucky; Fisher Auto Parts in Elizabethtown, Kentucky; O’Reilly Auto Parts in Leitchfield, Kentucky; and NAPA in Elizabethtown, Kentucky.
CHAPTER 1
INTRODUCTION AND HISTORY
Automobiles have been around since the late 1800s, and changes have come along to improve them in every imaginable way. The vehicles from the 1800s did not have an enclosed cab to protect the occupants from the elements.
History of Cabin Heating Systems
Closed-body cars first appeared in the early 1900s, and the occupants used gas lamps and gas burners to provide heat. These heating techniques were the same methods that horse-drawn carriages were using. As time passed by, manufacturers used engine exhaust heat as well as hot air off of the engine to produce a little heat for the cabin and its occupants.
Car manufacturers began using heated engine coolant in the 1930s, which was a more effective method to provide comfort. General Motors and the Nash brand were among the first companies to use heater cores to provide heat for the cabin of the vehicle. Another milestone that General Motors was involved in was the heated seats that were available on a few models. Development of heating systems on a wide sector of the market was somewhat slow because it was the late 1950s when most models had heating systems. By the 1960s, heating systems were standard equipment across most major car brands.
The heater hoses route the engine coolant into the heater core of this 1969 Chevrolet Camaro.
The climate control head on this 1969 Camaro has settings for blower speed, air temperature, and defrost. This system uses cables to move the doors on the duct box.
History of Air-Conditioning Systems
Keeping the driver and passengers comfortable in hot weather was also a challenge for car manufacturers. Techniques used in the early history of the car business included canvas covers, vent windows, and crank-style windows.
Providing shade to keep direct sunlight off of the occupants was an improvement over open-air vehicles. In addition, providing windows that could be positioned to provide increased velocity of the air provided more cooling capacity for the cabin.
Air-conditioning systems that used a pressurized refrigerant first appeared in the early 1930s. The Packard Motor Car Company was the first manufacturer to offer air-conditioning as an option around 1939. The system used by Packard was manufactured by Bishop and Babcock and was called the weather conditioner. This air-conditioning system was mounted in the trunk and involved a lot of plumbing and piping, which was a disadvantage because there were many places that could develop a leak. This system used a compressor that ran at all times and did not have any temperature adjustments. The $274 price for this system made it a very expensive option for that time period.
The windshield on this 1936 Rolls-Royce folds forward to allow increased airflow into the cabin to help keep the occupants comfortable in hot weather. This vehicle also has side windows and vent windows that operate with a crank.
This two-door 1957 Chevrolet Bel Air has side windows and vent windows that operate with a window crank arm. The vent window was a popular option that caused a strong airflow when it was opened up.
The window crank arms and door handle are within easy reach for the passenger of this two-door 1957 Chevrolet Bel Air.
Chrysler and General Motors began offering air-conditioning as an option