CCAS 3382 - AUTOMOTIVE SKILLS II

AIR CONDITIONING SYSTEM

GROUP 1

MUHAMMAD HAFIZ BIN SUHAINI 0615371

HAYATUN NAJIHIN BIN MOHD SAKOR 0732491
MOHD FAKHRIE SYAZWAN B. ABD HAMID 0734733
MOHD HAIRUDIN BIN ABDUL RASID 0810923
MOHD FARID BIN ISMAIL 0815461
MUHAMMAD AMMAR BIN MOHD IMRA 0819725

SECTION 2
SEMESTER II 2010/2011
 Introduction
► Air conditioning's main principles are Evaporation
and Condensation, then Compression and
Expansion.
► Hard tubing and flexible hoses connect all the
actual components of the air conditioning in your
car.
► Evaporation and condensation, expansion and
compression are the physics of why it works.
► There are five main components to the whole
system, namely the Compressor, Condenser,
Receiver-dryer, Expansion valve, and the
Evaporator.
►  The fluid that passes around the whole system
is the refrigerant. The refrigerant can evaporate
at a low temperature, and then condense again
at a higher pressure. In the bad old days, R-12
was the refrigerant used in almost all cars. It
was widely available, however it was found to be
a contributor to the hole in the earth's ozone
layer as it was a chlorofluorocarbon (CFC).
These refrigerants were discontinued, and all
cars after 1996 use a non-CFC fluid called R-
134A which is kinder to the environment. 
 How It Works
► Compressor: The compressor is the work horse of the air
conditioning system, powered by a drive belt connected to the
crankshaft of the engine. When the aircond system is turned on,
the compressor pumps refrigerant vapor under high pressure to
the condenser.
► Condenser: The condenser is a device used to change the high-
pressure refrigerant vapor to a liquid. It is mounted in front of the
engine's radiator, and it looks very similar to a radiator. The vapor
is condensed to a liquid because of the high pressure that is
driving it in, and this generates a great deal of heat. The heat is
then in turn removed from the condenser by air flowing through
the condenser on the outside.
► Receiver: The now liquid refrigerant moves to the receiver-dryer.
This is a small reservoir vessel for the liquid refrigerant, and
removes any moisture that may have leaked into the refrigerant.
Moisture in the system causes havoc, with ice crystals causing
blockages and mechanical damage.
► Expansion Valve: The pressurized refrigerant flows from the
receiver-drier to the expansion valve. The valve removes pressure
from the liquid refrigerant so that it can expand and become
refrigerant vapor in the evaporator.

► Evaporator: The evaporator is another device that looks similar to

a car radiator. It has tubes and fins and is usually mounted inside
the passenger compartment behind the fascia above the footwell.
As the cold low-pressure refrigerant is passed into the evaporator, it
vaporizes and absorbs heat from the air in the passenger
compartment. The blower fan inside the passenger compartment
pushes air over the outside of the evaporator, so cold air is
circulated inside the car. On the 'air-side' of the evaporator, the
moisture in the air is reduced, and the 'condensate' is collected and
drained away.

► Compressor: The compressor then draws in the low-pressure

refrigerant vapor to start another refrigeration cycle. The
refrigeration cycle then runs continuously, and is regulated by the
setting of the expansion valve.
 Basic Components
► 1) Compressor ► 2) Evaporator Core

► 3) Expansion Valve ► 4) Condenser

 Common Problems
► From time to time the A/C system needs to be recharged
to bring it back up to maximum efficiency.  Sometimes a
leak may cause loss of refrigerant and will need to be fixed
before refilling.  It's difficult to tell if a leak is present
without specific test equipment so let it up to a
professional.  
► In recent years, the EPA has phased out the use of R-12
Freon in all refrigeration systems and R-134 has become
the new standard.  If you have an older system with R-12
you may need to retrofit your system to handle the new R-
134 refrigerant.  Sometimes seals, hoses and even the
compressor need to be changed.  The problem arises when
the older seals and hoses are not compatible with the new
oils found in the R-134.
 Troubleshooting Steps
► Step 1: The air conditioner
utilizes a serpentine belt that
supplies power to rotate the
compressor, which is basically a
refrigerant pump. If the belt
fails the compressor has nothing
to drive it, inspect and replace
as needed to restore operation.
If belt is intact proceed to the
next step.
► Step 2: Check for
Compressor Clutch
Engagement - Turn the air
conditioner to the "on" position
and set controls to the coldest
setting. Start the engine and
allow idling. Then open the
hood and inspect the clutch at
the front of the compressor, is it
turning? If not, proceed.
 ► Step 4: Inspect for
► Step 3: Inspect Fuses -
Check under dash panel
and under hood power
distribution center.
Replace failed fuses as
needed, recheck system.
If the new fuse fails when
reinstalled a short circuit
is present and requires
diagnosing with a wiring
schematic, follow circuits
to locate short, repair as
needed and recheck
system.
Refrigerant Leaks - If the
system has a large leak and no
refrigerant remains it will not
activate. A refrigerant leak
detector is needed to inspect for
leak, but if you do not have a
leak detector there is an
alternative method. The air
conditioner system is designed
to run with oil suspended in the
refrigerant to lubricate the
system. Check for oily residue
outside the system by inspecting
all hoses, compressor,
condenser, evaporator or
receiver drier and replace any
component that has failed.
 Prices
► Basic service: RM 80.00
► Compressor:
- Recon: From RM 320.00
- Second Hand: From RM 200.00 – 300.00
- New: Above RM500
(All prices depend on the car’s model)

Chuan Kok Auto Parts Trading Sdn Bhd

1710 Jalan Kapar
41400 Klang
03-3291-4488
 Conclusion
► As simple as it sounds but car air conditioning
system is quite important especially in radical
weather. The smooth driving can be interrupted
when there is a problem with the air conditioning
system. It is important for us to have regular
maintenance on our car as each part is essential in
the running of the car. This also implies to the car
air conditioner system and all other systems in a
car. The driver needs to be more observant in any
changes on the car that affects the driving system
of the car.

* Pictures credited to 2carpros.com