Technical Service Training

Global Fundamentals
Curriculum Training – TF1010012S
Climate Control

5 6 60
4 7 80
3 RPM X 1000 8
VOL - PUSH ON
100 14
40 80
0 100 AM
120 4x4 FM SCN
16 FM1 ST
60
40 0 BASS TREB BAL FADE
H 20 18 F AUTO
2
1 20 km/
0
CD
SET

C
MPH 120
h
E
DISC
SEEK EJ

TUNE COMP

CD CD SHUFFLE
1 2 3 4 5 6

RSM SET
ON
ACC

CST
OFF
AUTO
4X4 ON

1
2
3 A/C
AC
MAX
4
A/C

1
2
3 A/C
AC
4 MAX
A/C

Student Information

FCS-13198-REF CG7968/S en 12/2001

Copyright © 2001 Ford Motor Company
Introduction Preface

Global fundamentals training overview

The goal of the Global Fundamentals Training is to provide students with a common knowledge base of the
theory and operation of automotive systems and components. The Global Fundamentals Training Curriculum
(FCS-13203-REF) consists of nine self-study books. A brief listing of the topics covered in each of the self-study
books appears below.

• Shop Practices (FCS-13202-REF) explains how to prepare for work and describes procedures for lifting
materials and vehicles, handling substances safely, and performing potentially hazardous activities (such as
welding). Understanding hazard labels, using protective equipment, the importance of environmental policy,
and using technical resources are also covered.

• Brake Systems (FCS-13201-REF) describes the function and operation of drum brakes, disc brakes, master
cylinder and brake lines, power-assist brakes, and anti-lock braking systems.

• Steering and Suspension Systems (FCS-13196-REF) describes the function and operation of the power-
assisted steering system, tires and wheels, the suspension system, and steering alignment.
• Climate Control (FCS-13198-REF) explains the theories behind climate control systems, such as heat transfer
and the relationship of temperature to pressure. The self-study also describes the function and operation of the
refrigeration systems, the air distribution system, the ventilation system, and the electrical control system.
• Electrical Systems (FCS-13197-REF) explains the theories related to electricity, including the characteristics
of electricity and basic circuits. The self-study also describes the function and operation of common
automotive electrical and electronic devices.
• Manual Transmission and Drivetrain (FCS-13199-REF) explains the theory and operation of gears.
The self-study also describes the function and operation of the drivetrain, the clutch, manual transmissions
and transaxles, the driveshaft, the rear axle and differential, the transfer case, and the 4x4 system.
• Automatic Transmissions (FCS-13200-REF) explains the function and operation of the transmission and
transaxle, the mechanical system, the hydraulic control system, the electronic control system, and the transaxle
final drive. The self-study also describes the theory behind automatic transmissions including mechanical
powerflow and electro-hydraulic operation.

• Engine Operation (FCS-13195-REF) explains the four-stroke process and the function and operation of the
engine block assembly and the valve train. Also described are the lubrication system, the intake air system,
the exhaust system, and the cooling system. Diesel engine function and operation are covered also.

• Engine Performance (FCS-13194-REF) explains the combustion process and the resulting emissions.
The self-study book also describes the function and operation of the powertrain control system, the fuel
injection system, the ignition system, emissions control devices, the forced induction systems, and diesel
engine fuel injection. Read Engine Operation before completing Engine Performance.

To order curriculum or individual self-study books, contact Helm Inc.

Toll Free: 1-800-782-4356 (8:00 am – 6:00 pm EST)
Mail: 14310 Hamilton Ave., Highland Park, MI 48203
USA Internet: www.helminc.com (24 hours a day, 7 days a week)

Service Training 1
Contents Introduction

Introduction...................................................................................................................................1
Preface........................................................................................................................................................................1
Global fundamentals training overview.........................................................................................................1
Contents......................................................................................................................................................................2
Lesson 1 – Climate control theory...............................................................................................4
General.......................................................................................................................................................................4
Objectives..........................................................................................................................................................4
At a glance.................................................................................................................................................................5
Climate control system....................................................................................................................................5
Theory........................................................................................................................................................................8
Heat energy......................................................................................................................................................8
Humidity.........................................................................................................................................................11
Heat movement..............................................................................................................................................11
Lesson 2 – Refrigeration system................................................................................................17
General.....................................................................................................................................................................17
Objectives........................................................................................................................................................17
Overview...................................................................................................................................................................18
Refrigerants.....................................................................................................................................................18
Handling refrigerant.......................................................................................................................................21
Components.............................................................................................................................................................24
Refrigeration system components................................................................................................................24
Operation..................................................................................................................................................................29
Lubricant.........................................................................................................................................................29
Refrigeration cycle is an expansion valve system......................................................................................30
Heating system...............................................................................................................................................36
Lesson 3 – Air distribution system............................................................................................37
General.....................................................................................................................................................................37
Objectives........................................................................................................................................................37
At a glance...............................................................................................................................................................38
Air distribution system...................................................................................................................................38
Air ventilation system....................................................................................................................................39
Air distribution ventilation system................................................................................................................40
Components.............................................................................................................................................................41
Air distribution ventilation system................................................................................................................41
Air distribution controls.................................................................................................................................43

Lesson 4 – Electrical control system.........................................................................................46

General.....................................................................................................................................................................46
Objectives........................................................................................................................................................46
At a glance...............................................................................................................................................................47
Electrical control system................................................................................................................................47
Components.............................................................................................................................................................48
Blower Switch................................................................................................................................................48
Blower motor.................................................................................................................................................48
Air condition compressor clutch controls....................................................................................................49
Thermostatic switch.......................................................................................................................................49
Pressure cycling switch.................................................................................................................................50
High and low-pressure switches...................................................................................................................51
Condenser temperature fan control..............................................................................................................52
2 Service Training
Introduction Preface

Climate control electrical controller..............................................................................................................52

Lesson 5 – Diagnostic procedure...............................................................................................53
General.....................................................................................................................................................................53
Objective.........................................................................................................................................................53
Overview..................................................................................................................................................................54
Symptom-to-system-to-component-to-cause diagnosis..............................................................................54
Workshop manual..........................................................................................................................................55
List of abbreviations...................................................................................................................56

Service Training 3
 Introduction Contents

Objectives

Upon completion of this lesson you will be able to:

• Explain the purpose and function of the climate control system.

• Describe the climate control system and identify the types.

• Identify the components of the climate control system.

• Explain the theory and operation of a climate control system.

Service Training 4
Lesson 1 – Climate control theory At a glance

Climate control system

5 6 7 60
4 80
RPM X 1000 8 40 80
100
120
3 60
140 VOL - PUSH ON

2 100
160
AM
40
4x4 FM FM1 ST SCN

H 20 180 F
BASS TREB BAL FADE
AUTO
1 20 km/h CD
SET

C
MPH 120 E
DISC
SEEK EJ

COMP
TUNE

CD CD SHUFFLE
1 2 3 4 5 6

RSM SET
ON
ACC

CST
OFF
4X4 AUTO ON

1
2

3 A/C
AC
MAX
4
A/C

1
2
3 A/C
AC
4 MAX
A/C

1 2 3
ACH003-A/VF

Electrical system components

1 Blower speed control
2 Air distribution control switch
3 Heating and cooling temperature control

The climate control system is designed to provide

comfort for the driver and passengers. The climate
control system maintains in-car air temperature and
humidity within a range that is comfortable for the
people inside and provides fresh clean air for
ventilation. A comfortable temperature inside the
vehicle helps keep the driver alert and attentive.

Service Training 5
At a glance Lesson 1 – Climate control theory

Climate control system (continued)

1
6

5 4
ACH002-A/VF

Air distribution system components

1 Defroster vents 4 Face vents

2 Air distribution ducts 5 Floor vent
3 Outside air intake 6 Dashboard

The air conditioning (A/C) system and the heating

system are known together as heating, ventilation and
air conditioning (HVAC) system. The HVAC system
controls heat, temperature, air distribution, and the
removal of humidity. The HVAC system uses an air
distribution system of ducts, vents and doors to direct
outside air or climate controlled air into the vehicle
passenger compartment. An electrical system
provides the operator control of the HVAC system.

6 Service Training
Lesson 1 – Climate control theory At a glance

1
7

2
6

3
5

ACH001-A/VF

Air conditioning components

1 Air conditioning compressor 5 Expansion valve or orifice tube

2 Air conditioning clutch assembly 6 Accumulator drier or receiver drier
3 Condenser 7 Evaporator
4 Air conditioning refrigerant lines

The HVAC system in a vehicle is divided into four

closely related subsystems:

• Refrigeration, A/C system

• Heating system

• Air distribution and ventilation system

• Electrical system

Service Training 7
Theory Lesson 1 – Climate control theory

Heat energy

Air conditioning is the control of heat. Heat is a form

of energy. Energy cannot be destroyed, but can be
converted into another form of energy. Air
conditioning systems use heat and energy from the
vehicle’s engine to remove unwanted heat from the
interior of the vehicle.

An example of energy conversion is a flame under a

container of water. The heat from the flame raises the
temperature of the water causing the water to boil.
The expanding gases or steam from the boiling water
can be used to create mechanical motion, another
form of energy.

Along with the concept of heat and heat energy comes

the concept of cold.

Heat measurement

Cold is merely the absence of heat. Cold is what is 1

left if all heat is removed. Heat will always travel to
cold. An example of this is a cooking pan on a hot
stove. The heat on the bottom of the pan will travel
toward the cold handle. Heat is relatively easy to 2
measure and its methods of movement are very
predictable and controllable.

Vehicle air conditioning systems create a cold spot

in the interior of the vehicle, giving the heat a cold 3
area to transfer to.

ACH004-A/VF

Heat movement
1 Pan
2 Handle
3 Heat source

8 Service Training
Lesson 1 – Climate control theory Theory

Temperature

Temperature or heat intensity is measured using a

˚C ˚F
thermometer. Heat intensity is important because the
140˚ 284˚
human comfort zone is 21-27°C (65-80°F). If the 130˚ 266˚
20˚ 248˚
temperatures fall above or below this comfort zone 110˚ 230˚

3 100˚ 212˚

the passengers may become uncomfortable. 90˚ 194˚

80˚ 176˚
70˚ 158˚
60˚ 140˚
50˚ 122˚ 1
40˚ 104˚
30˚ 86˚
20˚ 68˚
10˚ 50˚
2 0˚ 32˚
-10˚ 14˚
-20˚ -4˚
-30˚ -22˚
-40˚ -40˚
-50˚ -58˚

ACH005-A/VF

Thermometer
1 Human comfort zone
2 Water freezing point
3 Water boiling point

Service Training 9
Theory Lesson 1 – Climate control theory

Heat energy (continued)

Heat quantity

Heat quantity is measured in joules or British thermal

units (BTU). A typical wooden match produces 1,051
joules of heat. 4.2 joules is the amount of energy
17˚C 18˚C
required to raise the temperature of 1g of water one
degree Celsius. A liter of gasoline has approximately
1g 4.20 J 1g
117 million joules of heat energy. Heat energy can be
converted into mechanical energy by the engine to
move the vehicle.

HVAC systems must also transfer heat to energy to

and from the interior of the vehicle.
ACH007-A/VF
HVAC systems are rated in calories. Vehicle
designers must take into account the size of the
vehicle, number of passengers and possible sources of Heat Measurement in Calories
heat when designing a HVAC system.
Metric to English conversion table
1 gram = .0022 pound
251 cal = 1 BTU
1,055 J = 1 BTU
17°C = 62.6°F
18°C = 64.4°F

10 Service Training
 Lesson 1 – Climate control theory Theory

Humidity Heat movement

Humidity is the amount of water or water vapor in
HVAC systems can transfer heat out of a place
the air. The humidity of the air may vary from a dry
where it is not wanted and move the heat into a place
0% up to a very damp 100%. Humid cold air feels
where it is wanted. Several physical principles are
much colder than air that is dry and at the same
involved in this transfer of heat.
temperature. Humid hot air slows down the human
body’s ability to cool itself by evaporation and Heat is energy that moves from hot to cold. Cold is a
perspiration. lack of energy. The rate that heat moves is a factor of
the difference in the temperature between hot and
As with temperature, excessive humidity makes
cold areas. A large temperature difference moves heat
humans uncomfortable. Excessive humidity also puts
much faster than if two areas are almost the same
added strain on the air conditioning system. A car’s
temperature. The heat flow tends to make the hot item
air conditioner not only cools the interior of the
cooler and the cooler item warmer. If left alone, the
vehicle, it also removes the moisture from the air
two areas will become the same temperature.
flowing into the passenger compartment as the air
conditioning system operates. To cool a hot vehicle, the evaporator creates a cold
place inside the vehicle for the unwanted heat to
transfer to. Once the heat moves to this cool area, the
heat is then removed and transferred to the air outside
of the vehicle. The vehicle’s engine and HVAC
system make this a fairly simple process.

Service Training 11
Theory Lesson 1 – Climate control theory

Heat movement (continued)

Heat travel

Heat can travel on one or more of three paths:

conduction, convection and radiation.

Heat conduction
1
Conduction is the simplest way heat travels. An 2
example of conduction would be heating one end of a
metal wire. Heat applied to one end of the wire would
be conducted through the wire to the opposite end
4
until both ends of the wire become hot. Some
materials such as steel, copper and aluminum are 3
good heat conductors. Materials such as wood or
plastic are poor conductors of heat and are called ACH008-A/VF

insulators.
Conduction

1 Heat traveling from the center to ends

2 Metal rod
3 Heat source
4 Cold metal end

Heat convection
1 2
Convection is another type of heat transfer.
Convection occurs when material, such as an engine,
passes heat to the cooling system of the vehicle. As
the potential energy of the fuel is converted to
mechanical and heat energy by the engine combustion
process, the heat of the engine must be removed. The
liquid in the cooling system is pumped through the
ACH009-A/VF
engine, and the convection process transfers engine
heat to the liquid. The cooling system liquid then
takes this heated coolant to the radiator. The metal Convection
radiator uses the conduction process to remove the 1 Heat from the engine
heat from the liquid coolant and to the radiator fins. 2 Heater core
The radiator fins then pass the heat of the radiator to
the passing airflow through the radiator.

12 Service Training
Lesson 1 – Climate control theory Theory

Heat radiation

Radiation is another example of how heat can move.

Radiation occurs when heat rays pass from one
location to another without warming the air or
material that the rays are passing through. An
example of radiation is a vehicle on a cold sunny day.
If the vehicle’s interior is closed off from the outside
air temperature, the interior of the vehicle becomes
warmer than the outside air. This happens because
the sunlight is passing through the air, and light rays
are striking the exterior and interior of the vehicle.
When the light rays strike the interior and exterior of
the vehicle surface, the light energy is changed into
heat energy warming the vehicle. The cold outside air
ACH010-A/VF
that the light rays pass through is not heated.

Radiant heat

States of matter

The states of matter are solids, liquids, and gases. A

solid may be a cube of ice, and when heat is added to 1 2 3
the ice the solid ice cube will change state into a
liquid. If additional heat is added (to 100°C [212°F]) + = + =
the liquid will change state into a gas. The air
4 4
conditioning system works through a fluid called a
refrigerant. The refrigerant in an A/C system that is
ACH011-A/VF
functioning is always changing state from a liquid to a
gas and back to a liquid.
Changing states of matter

1 Ice cube
2 Liquid
3 Vapor or gas
4 Heat source

Service Training 13
Theory Lesson 1 – Climate control theory

Heat movement (continued)

Latent heat

Latent heat is the amount of heat that must be added

or removed from a liquid to make it change state. It is
called latent heat because you cannot measure it with 1
2
a thermometer. For example, if you heat 453 grams of
water at sea level to 100°C (212°F) you must continue
to apply at least 993,030 joules of heat energy to
convert it to steam. As you add these additional joules
the water the temperature remains unchanged. The
additional heat, called latent heat or hidden heat, 4
5 3
is the heat needed to change a substance from a liquid
to a vapor.
ACH048-A/VF

Latent heat movement

1 Add heat
2 Vapor
3 Liquid
4 Remove heat
5 Solid

14 Service Training
Lesson 1 – Climate control theory Theory

Latent heat of vaporization

100˚C 100˚C
2

993,030 J

ACH049-A/VF

Latent heat of vaporization

1 Lack of latent heat producing 1 gram of hot water
2 Latent heat producing 1 gram of steam

In an A/C system, latent heat of vaporization occurs

within the evaporator. When the refrigerant passes
through the evaporator, it absorbs heat from inside the
vehicle and begins to boil. As heat continues to be
absorbed, the refrigerant changes from a low-pressure
liquid into a low-pressure vapor.

Service Training 15
Theory Lesson 1 – Climate control theory

Heat movement (continued)

Latent heat of condensation

100˚C 100˚C
1

993,030 J

ACH050-A/VF

Latent heat of condensation

1 Latent heat producing 1 gram of steam
2 Lack of latent heat producing 1 gram of hot water

In an A/C system, latent heat of condensation occurs Pressure and boiling points
within the condenser. The condenser discharges heat
from the refrigerant into the outside air. As the Changing the pressure of a liquid changes its boiling
refrigerant cools, it condenses from a vapor to a point. Higher pressure increases the boiling point,
liquid. while lower pressure decreases the boiling point. An
air conditioning system also uses this principle to
remove heat from the interior of the vehicle. At sea
level, water boils at 100°C (212°F). The lower
atmospheric pressure at the top of a high mountain
may allow water to boil at only 86°C (187°F).
Refrigerants must have a very low boiling point.
Some refrigerants under pressure in an air
conditioning system may have boiling points as low
as -22°C (-7.6°F).

16 Service Training
Lesson 2 – Refrigeration system General

Objectives

Upon completion of this lesson you will be able to:

• Explain the purpose and function of the refrigeration system.

• Describe the refrigeration system and identify the types of refrigeration systems.

• Identify the components of the refrigeration system.

• Explain the theory and operation of the refrigeration system.

Service Training 17
Overview Lesson 2 – Refrigeration system

Refrigerants

R-12

1 2

ACH014-A/VF

Effects of chlorine on the ozone layer

1 Chlorine atoms from R-12

2 Ozone depletion

Auto air conditioning systems typically use one type In the mid-1980s, scientists discovered that chemicals
of refrigerant, R-134a. Older vehicles used a called chloro-fluorocarbons (CFC) were destroying
refrigerant called R-12, but this type of refrigerant is the ozone in the atmosphere. Ozone protects the earth
no longer in production. The R stands for refrigerant. from harmful ultraviolet rays released by the sun. One
Both chemicals are suitable A/C refrigerants because of the major contributors to CFCs in the atmosphere
they have very low boiling points. Though similar in was R-12, which often leaked into the atmosphere
many respects, R-12 and R-134a affect the during servicing of A/C systems. In 1987, many
environment differently. countries signed an international agreement calling
for the gradual phase-out of CFCs. As a result, R-12
R-12 is the common name for
was phased out of all new automotive A/C systems.
Dichlorodifluoromethane-12 CFC-12, a chemical
Many countries also have laws mandating that A/C
used in many types of refrigeration systems up until
technicians must be properly trained on refrigerant
about 1990. R-12 contains a single carbon atom,
extracting and reclaiming before working on an A/C
surrounded by two fluorine atoms and two chlorine
system.
atoms. The chemical formula for CFC-12 is
CCl 2 F 2. R-12 is a suitable refrigerant because of its
excellent ability to absorb large quantities of heat.

18 Service Training
Lesson 2 – Refrigeration system Overview

HFC134a or R-134a

Because of the environmental damage caused by

R-12, scientists developed an alternative refrigerant
called R-134a. Most vehicles manufactured from
1 F 2
1990 to the present use R-134a as an A/C refrigerant.
Unlike R-12, R-134a does not contain CFCs. Instead,
F C CI
it contains hydrofluorocarbons (HFCs), which do not
damage the ozone layer. Like R-12, R-134a has
CI 3
chemical properties that make it ideal for use as a
refrigerant. These include:
ACH013-A/VF

• Low boiling point of -26° C (15° F) at sea level

R-12 atom structure
• Ability to change temperature readily in response
1 Fluorine atom
to changes in pressure
2 Carbon atom
3 Carbon/chlorine atom

R-134a provides most of the benefits of R-12 without

the harmful atmospheric effects. The absence of
chlorine in R-134a makes it environmentally 1 H F 2
“friendly,” but R-134a can be flammable at certain
pressures and concentrations. F C C F

H F
3

ACH012-A/VF

R-134a atom structure

1 Hydrogen/fluorine atoms
2 Carbon atoms
3 Fluorine atom

Service Training 19
Overview Lesson 2 – Refrigeration system

Refrigerants (continued)

Refrigerant mixing

A/C systems that use one type of refrigerant cannot

use the other type. For example, you cannot use R-
134a to charge an older A/C system designed to use
R-12. Under no circumstances should R-12 and R-
134a be mixed in the same system. Mixing
refrigerants is called cross-contamination, and it can
seriously damage the A/C system. In addition,
identifying contaminated refrigerant during normal
diagnosis is difficult.

R-12 R-134a
Container color: White Container color: Light blue
Container marking: R-12 Container marking: R-134a
Container fitting size: 7/16" - 20 Container fitting size: 1/4" flare 1/2" – 16 ACME
Chemical name: Dichlorodifluoromethane Chemical name: Tetrafluoroethane
Boiling point: -29.70°C (-21.62°F) Boiling point: -25.15°C (-15.07°F)
Latent heat of vaporization: 9,071 calories or Latent heat of vaporization: 11,843 calories or
38,007 J or, 36 BTUs at 0° C (32°F) 49,622 J or 47.19 BTUs at 0°C (32°F)

20 Service Training
Lesson 2 – Refrigeration system Overview

Handling refrigerant

Technicians often remove or discharge refrigerants

from an A/C system during service. Depending on
how these refrigerants are processed after removal,
they can be classified as recycled, reclaimed, or
extracted.

Recycled refrigerant

Recycled refrigerant is cleaned to remove

contaminants produced during normal operation of
the A/C system. Mixing recycled refrigerant from a
non-vehicle mobile system or a building type A/C
system, for example, contaminates recycled mobile
vehicle refrigerant.

ACH015-A/VF

Refrigerant extracting and reclaiming machine

Reclaimed refrigerant

Reclaimed refrigerant is processed to the same

standards and purity as new refrigerant. This process
requires expensive equipment not ordinarily found in
dealership service departments. Reclaimed and
recycled refrigerant will perform equally well in all
mobile A/C systems.

Extracted refrigerant

Extracted refrigerant is simply removed and stored in

an approved container. This process is used when
servicing the refrigeration system and the refrigerant
must be removed and stored from the A/C system.

Service Training 21
Overview Lesson 2 – Refrigeration system

Handling refrigerant (continued)

Storing refrigerant
10˚C 32˚C 37˚C

Both R-12 and R-134a are gases at normal room

temperature, and they can be hazardous if stored
improperly. New refrigerant stored in its original,
properly filled container usually poses no safety
hazard. However, recycled refrigerant can be
dangerous if it is stored in the wrong type of container
1 2 3
or in an overfilled container. To prevent accidents
ACH016-A/VF
when handling recycled refrigerant, always follow the
rules below:
Heat and expanding gas
• Never save disposable refrigerant containers for
1 60% full
reuse. Remove all refrigerant and dispose of the
2 100% full
containers properly.
3 Bursting or high temperature
• Use only containers approved for refrigerant.

• Never fill a container to more than 60% of

container capacity.

• Never store refrigerant containers in direct sun or

heat. High temperature causes the gas to expand,
which increases the pressure in the container and
may cause the container to burst.

22 Service Training
Lesson 2 – Refrigeration system Overview

Refrigeration fittings

Refrigeration fittings allow the system to be checked

for proper operating pressures and to empty or fill the
system as needed. To prevent cross contamination of 1 2
different types of refrigerants such as R-134a and
R-12, refrigeration systems use different styles of
fittings. There are several differences between R-134a
and R-12 refrigeration fittings. The most significant
difference is that R-134a uses a special coupler that
cannot be used on R-12 systems. The new fittings on
ACH017-A/VF
the R-134a prevent excessive loss of refrigerant to the
atmosphere. R-134a refrigeration fitting types

1 R-134a low side fitting

2 R-134a high side fitting

1 2

ACH051-A/VF

R-12 refrigeration fittings types

1 R-12 high side fitting

2 R-12 low side fitting

Service Training 23
Components Lesson 2 – Refrigeration system

Refrigeration system components

Like the liquid in the engine cooling system, the

refrigerant in an air conditioning system absorbs,
carries, and releases heat. To do this, the A/C system
utilizes many components to move heat.

Evaporator

The evaporator is located near the interior of the

vehicle. The evaporator removes heat from the
passenger compartment and transfers the heat to the
refrigerant. Refrigerant enters the evaporator as a
cool, low-pressure liquid mist, which circulates
through the evaporator’s tubes and fins much like
coolant circulates through an engine’s radiator. An
electric blower fan forces warm air from the
vehicle’s interior over the surface of the evaporator.
The refrigerant absorbs heat as it changes from a
liquid to a gas. The refrigerant then exits the
evaporator, carrying the heat with the refrigerant as a ACH018-A/VF

warm, low-
pressure gas.
Evaporator operation

24 Service Training
Lesson 2 – Refrigeration system Components

Compressor

The compressor is the refrigerant pump for the A/C

system. A drive belt and pulley connect the
compressor to the engine crankshaft, which provides
the power to operate the compressor. The compressor
draws in warm, low-pressure gas from the evaporator,
which drastically raises the pressure and temperature
of the gas. The gas is passed on to the condenser. The
1
compressor operates only with refrigerant in its
gaseous state. Liquid refrigerant in the compressor 2
damages the compressor.

Compressors create suction and pressure. Pistons or 3

other forms of internal compressor components create
4
pressure and suction, moving the refrigerant.

The suction port allows the compressor to draw in gas

from the evaporator. The compressor then compresses
the gas and discharges the gas out of the discharge
5
port to the refrigeration lines and to the condenser.

ACH032-A/VF
The clutch assembly allows the compressor to cycle
on and off using the HVAC electrical controls.
Compressor components
The relief valve protects the system from excessive
1 Suction port
refrigerant pressures. If system pressure becomes too 2 Discharge port
high the valve opens and refrigerant is vented to the 3 Pulley
outside air. 4 Clutch assembly
5 Relief valve

Service Training 25
Components Lesson 2 – Refrigeration system

Refrigeration system components (continued)

Condenser

The condenser is located in front of the radiator. The

condenser receives hot, high-pressure refrigerant gas 1
from the compressor and transfers the heat to the
outside air. Like the evaporator, the condenser 2
circulates refrigerant through a series of tubes and
fins. A fan draws outside air over the condenser’s 3
surface area, allowing the hot refrigerant to pass its
heat to the air. As the refrigerant cools, it changes ACH019-A/VF

from a high-pressure gas to a high-pressure liquid.

The efficiency of the condenser is critical to A/C Condenser operation
operation. The outside air must absorb the stored heat 1 High-pressure hot vapor
from the vehicle interior plus the additional heat that 2 High-pressure hot liquid
results from compressing the gas. The more heat 3 High-pressure warm liquid
transferred by the condenser, the more cooling the
evaporator can provide. A larger capacity condenser
and a more efficient fan will reduce the interior
temperature significantly.

26 Service Training
Lesson 2 – Refrigeration system Components

Receiver/drier

Located near the outlet of the condenser on the high

pressure side of the A/C system, the receiver/drier,
used in conjunction with an expansion valve, filters
moisture and foreign matter from the liquid
refrigerant and serves as a storage area for refrigerant. 1
The receiver/drier may also have electrical controls 4
2
and service ports for system operation and servicing.

ACH022-A/VF

Receiver/drier components

1 Line to the evaporator

2 Line from the condenser
3 Pressure switch
4 High-pressure service port

Accumulator/drier

The accumulator is used in A/C systems with an

1
orifice tube. The accumulator is located after the
evaporator and before the compressor, on the low-
pressure side of the A/C system. The accumulator
2
functions very much like the receiver/drier in an
expansion valve system.

ACH021-A/VF

Accumulator

1 Refrigerant tube
2 Filter media

Service Training 27
Components Lesson 2 – Refrigeration system

Refrigeration system components (continued)

Expansion valve

The expansion valve regulates the flow of refrigerant 1

to the evaporator. To get maximum cooling potential,
the pressure of the liquid refrigerant must be lowered 5
before it enters the evaporator. At lower pressure, the 2
refrigerant’s temperature and boiling point drop,
4
allowing it to absorb more heat as it passes through
3
the evaporator. A bulb on the evaporator sends
information about evaporator temperature through a
capillary tube. This tube is attached to the diaphragm
on the expansion valve. If the evaporator becomes too
cold, the diaphragm pulls the needle-shaped pintle up,
closing the valve and restricting refrigerant flow. As ACH023-A/VF

the evaporator temperature rises, the diaphragm

presses down on the pintle, opening the valve and Expansion valve
letting more refrigerant through.
1 Diaphragm
2 Capillary tube
3 Temperature sensing bulb
4 Valve
5 Pintle

Orifice tube
1
2
Like an expansion valve, an orifice tube divides the
high and low-pressure parts of the A/C system. The
orifice tube has a fixed opening. The flow rate of the
refrigerant through the opening is determined by the
cycling of the compressor.

5 4 3
ACH024-A/VF

Orifice tube components

1 Refrigeration line
2 High-pressure liquid from condenser
3 Filter screen
4 Orifice
5 Low-pressure liquid to the evaporator

28 Service Training
Lesson 2 – Refrigeration system Operation

Lubricant

Refrigeration oil lubricates the moving parts and seals In an A/C system, the components hold the refrigerant
of an A/C system. The oil flows with the refrigerant oil. The compressor helps to mix the oil with the
throughout the system. Refrigeration oil and motor oil
refrigerant and circulates it throughout the system.
are different. Never use motor oil in an A/C system.
When replacing an A/C component, the oil that is
trapped in the component that is being replaced must
Mineral oil and PAG oil
also be replaced. Service manuals contain charts
The type of refrigeration oil used in an A/C system describing how much oil to add for various
depends on the type of refrigerant. When engineers component replacements.
develop a refrigerant, they simultaneously develop
If an A/C system develops a leak, refrigeration oil
the lubrication oil used with it.
will appear at the site of the leak. Any leaking
R-12 A/C systems use mineral oil as a lubricant. refrigerant evaporates immediately. The amount of
R-134a systems use an oil made of polyalkylene oil lost depends on the size of the leak and the length
glycols, commonly called PAG oil. PAG oil and of time it was leaking. After you repair a leak, replace
mineral oil are completely incompatible and should the amount of lost oil. Carefully measure the oil
never be mixed. removed during evacuation and replace it with a
slightly greater amount. If lost oil is not replenished
Characteristics of refrigeration oil severe damage may occur.

Refrigeration oil, either mineral or PAG oil, is highly

refined and free of the additives and detergents found
in conventional motor oil. Refrigeration oil flows
freely at temperatures well below freezing, and it
includes an additive to prevent foaming in the A/C
system. Refrigeration oil readily absorbs moisture.
If stored improperly, the oil becomes unusable. For
example, an unsealed container of PAG oil becomes
saturated with two percent water if left in a humid
climate for five days. If you use saturated oil in an
A/C system, acids form, damaging seals and other
components. Always seal refrigerant oil properly
after use, and never reuse oil removed from an
operating A/C system.

Service Training 29
Operation Lesson 2 – Refrigeration system

Refrigeration cycle in an expansion valve system

Vehicle A/C systems use the physical principles of

heat transfer and movement. Vehicle A/C systems 3
2
are either orifice tube or expansion valve type
1
systems. The A/C system is divided into two parts: a
4
low- pressure side and a high-pressure side.
Refrigerant boils or evaporates in the low side and
condenses in the high side.

As the refrigerant flows through a complete cycle, the

refrigerant undergoes two changes in pressure and 7
5
changes of state. The A/C system can be divided into
four sections. The horizontal line in the graphic
divides the cycle into a “high-pressure side” on top 6
and a “low-pressure side” on the bottom. The high- ACH025-A/VF

pressure side starts at the compressor outlet, extends

through the condenser and receiver/drier, and ends at Refrigeration cycle
the expansion valve.
1 Compressor
2 Condenser
When refrigerant leaves the expansion valve, its
3 Heat to atmosphere
pressure drops and it enters the low-pressure side. The
4 Receiver/drier
low-pressure side extends through the evaporator and
5 Expansion valve
into the compressor’s inlet.
6 Heat from vehicle interior
The vertical line in the illustration marks the points 7 Evaporator
where the refrigerant changes state. On the left side of
the circuit the refrigerant is a vapor; on the right side
it is a liquid.

30 Service Training
Lesson 2 – Refrigeration system Operation

Refrigeration cycle (compressor)

The refrigeration cycle begins at the compressor. The

compressor draws in low-pressure vapor (about 206
2
kPa [30 psi]) from the evaporator and compresses it to
1
about 1,207 kPa (175 psi). A drive belt on the engine
3
turns the compressor pulley, which spins the
compressor when the compressor’s magnetic clutch is
engaged. The system monitors refrigerant pressure
and activates the compressor only when needed.

The compressor pushes vapor through the outlet to the 5

4
condenser. The expansion valve is like a plug in the
circuit that allows pressure to build on the high-
pressure side of the system. This hot, high-pressure
vapor carries heat picked up in the evaporator, as well ACH026-A/VF
as additional heat from the increased pressure
provided by the compressor. At this point, the Refrigeration flow
refrigerant may be as hot as 54° C (130°F). 1 Compressor
2 Condenser
3 Receiver/dryer
4 Expansion valve
5 Evaporator

Service Training 31
Operation Lesson 2 – Refrigeration system

Refrigeration cycle in an expansion valve system (continued)

Refrigeration cycle (condenser)

Hot, high-pressure refrigerant gas or vapor from the 2

compressor enters the condenser under high pressure 1
of about 1,206 kPa (175 psi), making the refrigerant 3
boiling point also higher. In addition, the difference
between the temperature of the outside air and the
refrigerant is great, so the refrigerant will quickly
release heat to the air flowing over the surface of the
condenser. The hot gas at approximately 54°C
5
(130°F) quickly cools below its high boiling point. 4
As the vapor condenses to a liquid, it releases large
amounts of heat or latent heat of condensation.
Airflow across the condenser decreases when the ACH027-A/VF

vehicle is not moving or in stop-and-go traffic. To

Refrigeration flow
compensate, most A/C systems include an electric fan
to supply additional airflow when needed. 1 Compressor
2 Condenser
3 Receiver/dryer
4 Expansion valve
5 Evaporator

32 Service Training
Lesson 2 – Refrigeration system Operation

Refrigerant cycle (receiver/drier)

After flowing through the receiver/drier, which

removes moisture and contaminants, the refrigerant
next enters the expansion valve. The expansion valve 2
restricts the flow of refrigerant, allowing only a small 1
amount to pass through on its way to the evaporator. 3
Refrigerant pressure on the high side of the expansion
valve can be as high as 1,723 kPa (250 psi) or more.
The expansion valve reduces that pressure to about
206 kPa (30 psi) on the low side. At this low
pressure, the temperature of the liquid refrigerant
5
drops from about 54°C (130°F) to about -1°C (30°F) 4
and its boiling point decreases. As the refrigerant
passes through the expansion valve, it is atomized, or
turned into a fine, liquid mist. This process increases ACH028-A/VF

the surface area of the refrigerant so it easily absorbs

heat when it passes through the evaporator. Refrigeration flow

1 Compressor
2 Condenser
3 Receiver/dryer
4 Expansion valve
5 Evaporator

Service Training 33
Operation Lesson 2 – Refrigeration system

Refrigeration cycle in an expansion valve system (continued)

Refrigeration cycle (evaporator)

As the refrigerant flows into the evaporator, the 2

refrigerant is a cold, low-pressure liquid mist. At this 1
low temperature, (about -1°C [30°F]) the refrigerant 3
readily picks up heat from the passenger
compartment. An electric blower fan pushes warm
interior air over the evaporator, where it gives up its
heat and returns to the passenger compartment as cool
air. Since the refrigerant’s boiling point is lower, it
5
quickly changes into a gas, allowing it to store large 4
amounts of heat as latent heat of vaporization. After
picking up heat in the evaporator, the refrigerant gas
is drawn into the inlet side of the compressor, where it ACH029-A/VF

begins another refrigeration cycle.

Refrigeration flow

1 Compressor
2 Condenser
3 Receiver/dryer
4 Expansion valve
5 Evaporator

34 Service Training
Lesson 2 – Refrigeration system Operation

Orifice tube system

An orifice tube system is similar to an expansion

valve system. However, since the orifice tube is a 1 2
fixed size, the tube must flood the evaporator to work
properly under all conditions. As the refrigerant
passes through the evaporator, most of it changes into
gas and then travels to the accumulator. The
accumulator replaces the receiver/drier in the system. 5
The accumulator/drier separates the liquid refrigerant
from the refrigerant gas and also removes moisture
and contaminants. This prevents liquid refrigerant
3
from getting back into the compressor, and allows
higher heat loads by keeping the remaining liquid on
4
hand.
ACH030-A/VF

Orifice system components

1 Compressor
2 Condenser
3 Accumulator/drier
4 Orifice tube
5 Evaporator

Service Training 35
Operation Lesson 2 – Refrigeration system

Heating system

2
ACH033-A/VF

Heating system components

1 Heater core
2 Radiator
3 Engine

The heating system works in conjunction with the has tubes with fins also like the A/C evaporator.
engine coolant system to transfer engine heat to the Heater cores are normally mounted in tandem next to
vehicle interior. The main components of the heating A/C evaporators and use the same blower motor and
system are the engine, heater hoses, heater core, air distribution system. The heat from the coolant is
electric blower motor fan and a heat shutoff device. transferred to the air passing through it by the blower
Hot engine coolant is moved by a coolant pump motor. The heated air is then moved through the
through the heater hoses to the heater core. The heater vehicle by the air distribution system.
core is like the radiator of the engine. The heater core

36 Service Training
Lesson 3 – Air distribution theory General

Objectives

Upon completion of this lesson you will be able to:

• Explain the purpose and function of the air distribution system.

• Describe the air distribution system.

• Identify the components of the air distribution system.

• Explain the theory and operation of the air distribution system.

Service Training 37
At a glance Lesson 3 – Air distribution theory

Air distribution system

The HVAC is a combined heating and air conditioning

unit. The heating and A/C system provides a desired 1
comfort zone in the passenger compartment by
controlling temperature and humidity. As weather
conditions change, the system must allow for changes
in temperature and desired airflow direction out of the
dashboard vents.

The operator can select heating or cooling and direct

this air to the dashboard vents using; temperature
blend doors, fresh air doors and vent/face doors 2
located behind the dashboard.
3
ACH034-A/VF

Air distribution flow

1 Defroster
2 Face vents
3 Floor vents

38 Service Training
Lesson 3 – Air distribution theory At a glance

Air ventilation system

ACH043-A/VF

Vehicle ventilation system airflow

The ventilation system provides fresh air into the

interior of the vehicle. Air entering a point at the front
of a vehicle is allowed to flow through the interior of
the vehicle and exits at vents or openings in the door
jambs or exit points to the outside air. The ventilation
system has some form of control to allow air to flow
or not flow through a vehicle depending on the
setting of the air distribution system. The ventilation
system uses the HVAC system to provide ventilated
air to the interior of the vehicle. Some vehicles use an
air filter to remove dust and pollen from the inlet air
side of the ventilation system.

Service Training 39
At a glance Lesson 3 – Air distribution theory

Air distribution ventilation system

Blower fan
3
The blower fan draws air in through the 1 2
fresh/recirculated air door. Depending on the air
distribution system settings, the blower draws air
through the evaporator for cooling, heating, or a
combination of both. The blower fan has adjustable
speeds for control of airflow velocity.

ACH036-A/VF

Blower fan operation

1 Heater core
2 Evaporator
3 Blower fan

Fresh/recirculated air door

Air first enters the system through the 1 2

fresh/recirculated air door. The system draws outside 3

air into the air distribution system either by the force

of the forward motion of the vehicle or with the
assistance of a fan. During normal operation, the fresh
air option provides fresh air to the A/C evaporator and
the heater core. If the operator selects to recirculate
4
the interior vehicle air the fresh air door closes off the
outside air passage and recirculates cool,
5
dehumidified air or heated air from the HVAC
system.
ACH035-A/VF

Door control components

1 Heater core
2 Evaporator
3 Fresh/recirculated air door
4 Fresh air door

40 Service Training
Lesson 3 – Air distribution theory At a glance

5 Recirculated air control

Service Training 41
Lesson 3 – Air distribution theory Components

Temperature blend door

The temperature blend door controls airflow to the

evaporator and heater core. With the system set to the
cool position, the temperature blend door blocks all 1 2
airflow to the heater core. When the door is partially
open, the air discharged into the passenger
compartment is a combination of heated air, unheated
air and cooled air.

ACH037-A/VF

Temperature blend door operation

1 Heater core
2 Evaporator
3 Temperature blend door

Defroster door
1
The defroster door redirects all airflow to the 2 3
windshield. When the operator selects the defrost
position, a door blocking the defroster passages
opens, and other doors for the floor and upper vents
close. This arrangement provides maximum airflow
to the windshield area.
4

ACH038-A/VF

Defroster door operation

1 Vent doors closed
2 Heater core
3 Evaporator
4 Defroster door

Service Training 41
Components Lesson 3 – Air distribution theory

Air distribution ventilation system (continued)

Vent/face heater doors

1
The vent/face and heater doors direct air either to the 2 3
floor vents or the upper vents. If the operator selects
the multiple-level position, air flows to both sets of
vents.

ACH039-A/VF

Vent/face heater door operation

1 Vent doors
2 Heater core
3 Evaporator
4 Defroster door

42 Service Training
Lesson 3 – Air distribution theory Components

Air distribution controls

5
3

ACHO40-A/VF

Cable system door controls

1 Floor defrost/door linkage
4 Floor defrost door
2 Function selector cable
5 Control head at dashboard
3 Temperature cable

Air distribution doors can be controlled using steel or

wire-like cables, engine vacuum or electrically
actuated door controls.

Service Training 43
Components Lesson 3 – Air distribution theory

Air distribution controls (continued)

Cable type air distribution system door controls

The most basic form of air distribution door control is

the cable. This type of control uses a manually
operated lever or knob that pivots in the center and
has a cable attached to one end. As the lever of knob
is moved, the cable pulls or pushes an arm that is
connected to the door being controlled. This type of
control can be used on any of the distribution doors.

Vacuum motor type air distribution system door

controls
1
Vacuum motors are also controlled by the position of 2

knobs or levers. When a lever or knob is pushed or

pulled, vacuum is allowed to flow against a rubber
diaphragm inside the vacuum motor. With vacuum
on one side of the rubber diaphragm and atmospheric
pressure on the opposite side the diaphragm forces a
rod that is attached to it and opens or closes an air
distribution door.

ACH042-A/VF

Vacuum system door controls

1 Vacuum line
2 Vacuum motor
3 Air inlet duct door

44 Service Training
Lesson 3 – Air distribution theory Components

Electronic actuator controls/air distribution

system door controls

Electronic actuators provide precise movement of air 2

distribution door controls and can provide feedback to 1
a computer operating them. Pushbuttons, levers or
knobs can all be used to operate the electronic door
actuator.

ACH041-A/VF

Electronic system door controls

1 Electronic door actuator motor
2 Temperature blend door pivot point
3 Actuator arm

Service Training 45
General Lesson 4 – Electrical control system

Objectives

Upon completion of this lesson you will be able to:

• Explain the purpose and function of the electrical control system.

• Describe the electrical control system.

• Identify the components of the electrical control system.

• Explain the theory and operation of the electrical control system.

46 Service Training
Lesson 4 – Electrical control system At a glance

Electrical control system

1
2
OFF

A/C

MAX
A/C

7 3

ACH052-A/VF

Electrical control system components

1 Blower switch 4 Electronic climate control module
2 Thermostatic switch 5 A/C compressor
3 Pressure cycling switch/high and low pressure 6 Blower motor
switches 7 Electronic door actuator

The electrical control system provides the operator

control of blower motor speeds, discharge air
temperature, airflow distribution and HVAC system
controls and protection devices.

Service Training 47
Components Lesson 4 – Electrical control system

Blower switch

The blower switch controls the on and off operation

of the blower motor and may also be used to control
blower speed or air distribution discharge volume.
One side of the switch is wired to a battery source ˚C

and the other side of the blower switch sends voltage

to the blower motor when the vehicle operator moves A/C

the switch to the ON position.

ACH053-A/VF

Blower switch and controls

Blower motor

The blower motor, after receiving electrical power

from the blower switch, rotates a fan that pushes or 1
pulls air past the heater core and evaporator, cooling
or heating the passing air depending on climate
temperature control settings. The air is then routed to
the air distribution system.

4 3
2

ACH044-A/VF

Blower motor components

1 Evaporator
2 Refrigerant inlet from evaporator
3 Refrigerant outlet from evaporator
4 Blower motor assembly

48 Service Training
Lesson 4 – Electrical control system Components

Air conditioner compressor clutch controls

The air conditioner compressor has to have some

means to turn the compressor on and off to prevent
damage and prevent the evaporator from freezing.
2
1
The air conditioning compressor clutch works by
electricity and magnetism. The clutch allows the
compressor to be turned on and off using electrical
signals. When electrical power flows to the clutch, a
magnetic force is created and this force moves a 3
friction disk against the rotating compressor pulley. ACH054-A/VF

The compressor is now linked through the clutch to

the engine drive belt. The engine A/C compressor A/C compressor clutch components
drive belt turns the shaft of the compressor and the 1 Friction disk and clutch assembly
refrigeration begins. 2 A/C compressor
3 Belt driven pulley

Thermostatic switch
1
Power from the A/C on and off switch operated by
the vehicle operator flows through the thermostatic 2

switch before flowing out to the A/C clutch. If the

evaporator is warm and is not in danger of freezing,
power is allowed to flow through the thermostatic
switch to the A/C compressor clutch. This electrical
power allows the clutch to engage and the 3
compressor to operate. The thermostatic switch has a ACH055-A/VF

long probe that is filled with a substance that expands

or contracts when hot or cold. The expansion or Thermostatic switch components
contraction opens or closes electrical contacts inside 1 Power input terminal
the switch. The thermostatic switch does not allow 2 Power output terminal
power to flow through the thermostatic switch and to 3 Sensing probe
the A/C clutch when the evaporator becomes too
cold. The thermostatic switch is normally used on
A/C systems where an expansion valve is used.

Some systems use a temperature sensor and an

electronic control module instead of a thermostatic
switch to cycle the compressor clutch.

Service Training 49
Components Lesson 4 – Electrical control system

Pressure cycling switch

The pressure cycling switch works in the same

fashion as the thermostatic switch. The pressure 2
cycling switch monitors pressure in the accumulator
or receiver/drier system and shuts off the power 1
3
supply to the A/C compressor clutch if pressure rises
or falls below the manufacturer’s specifications.

ACH046-A/VF

Pressure cycling switch components

1 Refrigerant inlet
2 Pressure cycling switch
3 Refrigerant outlet
4 Accumulator receiver/drier

50 Service Training
Lesson 4 – Electrical control system Components

High and low-pressure switches

High and low-pressure switches monitor refrigerant

pressure in both the high and low sides of the
refrigeration system. The high side pressure relief
switch and valve protects the system from excessive 1

high side system pressure that may cause an A/C

component to burst. The low side pressure switch
protects the system from working if there is a loss of
system refrigerant. The lubricating oil in the A/C
system flows with the refrigerant, and if refrigerant
pressure is lost the oil cannot circulate and system
damage occurs. Both the low and high side pressure
switches allow or prevent electrical power from
flowing to the A/C compressor clutch, allowing or 2
preventing compressor operation.

ACH047-A/VF

Pressure switches

1 High-pressure switch
2 Low-pressure switch

Service Training 51
Components Lesson 4 – Electrical control system

Condenser temperature fan control

The condenser temperature fan control monitors the

temperature of the refrigerant flowing through the
condenser. If the control monitor determines that the
temperature of the refrigerant is too high, the engine
temperature coolant fan turns on and the refrigerant
temperature is lowered. The refrigerant is cooled by
the passing airflow that is pulled through the 1
condenser by the engine coolant fan.

ACH056-A/VF

Temperature fan control sensor location

1 Condenser
2 Condenser temperature sensor

Climate control electrical controller

Many vehicles have electronic climate control

systems to monitor interior vehicle temperature
settings and adjust the vehicles interior temperature
and air distribution accordingly. The climate control
electrical controller takes in information such as
refrigerant temperature and pressure, heater and fresh
air door position along with blend door position to
adjust the interior output air to the desired
temperature. The climate control electrical controller
also communicates with other vehicle computers to
allow the system and the vehicle to perform as
intended by the designer.

52 Service Training
Lesson 5 – Diagnostic process General

Objective

Upon completion of this lesson you will be able to:

• Explain the symptom-to-system-to-component-to-cause diagnostic process.

Service Training 53
At a glance Lesson 5 – Diagnostic process

Symptom-to-system-to-component-to-cause diagnostic process

Diagnosis requires a complete knowledge of the For example, if the A/C system is low on refrigerant,
system operation. As with all diagnosis, a technician adding refrigerant may correct the problem for a short
must use symptoms and clues to determine the cause time but finding and repairing the leak that is causing
of a vehicle concern. To aid the technician when the refrigerant to leak corrects the problem and
diagnosing vehicles, the strategies of many successful repairs the vehicle correctly the first time.
technicians have been analyzed and incorporated into
a diagnostic strategy and into many service
publications.
1
Symptom-to-system-to-component-to-cause
diagnostic process

Using the "Symptom-to-System-to-Component-to-

Cause" diagnostic process provides you with a logical 2 2 2
method for correcting customer concerns:

• First, confirm the "Symptom" of the customer’s

concern.

• Next, determine which "System" on the vehicle

3 3 3 3 3 3 3
could be causing the symptom.

• Once you identify the particular system, determine

which "Component(s)" within that system could
be the cause for the customer concern.
4 4 4
• After determining the faulty component(s) you
should always try to identify the cause of the
ACH057-A/VF
failure.

In some cases parts just wear out. However, in other 1 Symptom

instances something other than the failed component 2 Vehicle systems
3 Components
is responsible for the problem.
4 Causes

54 Service Training
Lesson 5 – Diagnostic process At a glance

Workshop literature

The vehicle workshop literature contains information

about climate control diagnostic steps and checks,
such as preliminary checks, verification of customer
concern or special driving conditions, road test, and
diagnostic pinpoint tests.

Service Training 55
Climate control List of abbreviations

A/C Air Conditioning HVAC Heating Ventilation Air Conditioning

BTU British Thermal Units J Joule

x 251 = 1 calorie 1 Joule = .238 CAL or .000947 BTU

CAL Calories x .0039 = BTU kPa kiloPascals x 0.145 psi,

100 kPa = 1 bar

C° Celsius
(C° x 1.8) + 32 = Fahrenheit PAG Polyalkaline glycol (a synthetic oil)

F° Fahrenheit psi pounds per square inch x 6.89 = kPa

(F° x 0.556) – 32 = Celsius

Gasoline Petrol

g Gram

56 Service Training