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COURSE OF STUDY

AUTOMOTIVE TECHNICIAN (P-119-1)


MODULE 11 : AIR-CONDITIONING SYSTEM REPAIR
Module Synopsis
This module is developed for students to acquire knowledge and skills in air-conditioning system repair. At the end of this module trainees will
be able to :
identify air-conditioning system location
remove air-conditioning belt
remove air-conditioning tensioner assembly
install air- conditioning tensioner assembly and belt
discharge refrigerant from air-conditioning system
remove evaporator air filter
install evaporator air filter
remove cooling unit assembly
check cooling unit components
install cooling unit assembly
recharge refrigerant in air-conditioning system

Module Objectives
Carry out air-conditioning system repair using hand tools set, special tools, air-conditioning belt, belt tensioner assembly, air-conditioner service
manual, fender cover, lubricant/grease, replacement parts, wheel stopper, safety stands, personal protection equipment, recovery and recycle
machine, refrigerant oil, and environmental act so that air-conditioning system location identified, air-conditioning belt and air-conditioning
tensioner assembly removed, air-conditioning tensioner assembly and belt installed, refrigerant from air-conditioning system discharged,
evaporator air filter removed, evaporator air filter installed, cooling unit assembly removed, cooling unit components checked, cooling unit
assembly installed and refrigerant in air-conditioning system recharged in accordance with manufactures specifications.

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Module Content
Task No
10.01 Replace air-conditioning belt and tensioner assembly
10.02 Replace air-conditioning evaporator air filter
10.03 Recover and recycle vehicle air-conditioning refrigerant

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STEPS

KNOWLEDGE

PERFORMANCE

HRS

DELIVERY
MODE

ASSESSMENT MODE
Knowledge (D)

1. Identify airconditioning system


location

1.1 Purpose of air-conditioning


system
1.2 Types of air-conditioning
system components
1.3 Air- conditioning system
component location

1.1 Determine airconditioning system


component location
Attitude/Safety:
Meticulous when
interpreting service
manual

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Lecture

Demonstration and
Observation

Performance (A/C)
Air-conditioning
system component
location
Detach airconditioning
belts from pulley
Detach tensioner
assembly
Fix the airconditioning

STEPS
2. Remove airconditioning belt

KNOWLEDGE

PERFORMANCE

2.1 Types of air-conditioning


belt
2.2 Procedures of removing airconditioning belt
2.1 Detach air-conditioning
belts from pulley
2.2 Determine serviceability
of belt
Attitude/Safety:
Use fender cover

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HRS

DELIVERY
MODE

Lecture

Demonstration and
Observation

ASSESSMENT MODE
tensioner assembly
and belt
Adjust belt tension
according to
specification
Tighten airconditioning
tensioner assembly to
specifications
Types of airconditioning
refrigerant
Set up recovery and
recycle machine in
air-conditioning
system

STEPS
3. Remove airconditioning
tensioner assembly

KNOWLEDGE

PERFORMANCE

3.1 Tensioner assembly


construction
3.2 Types of air-conditioning
tensioner
3.3 Types of air-conditioning
pulley with bearing
3.1 Determine serviceability
tensioner assembly
3.2 Detach tensioner
assembly

HRS

DELIVERY
MODE

Lecture

Demonstration and
Observation

Lecture

Demonstration and
Observation

Attitude/Safety:
Meticulous when
removing tensioner
4. Install airconditioning
tensioner assembly
and belt

4.1 Procedures of installing airconditioning tensioner


assembly and belt
4.2 Specifications of belt
tension and tightening
torque

4.1 Fix the air-conditioning


tensioner assembly and
belt
4.2 Adjust belt tension
according to
specification
4.3 Tighten air-conditioning
tensioner assembly to
specifications

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ASSESSMENT MODE

Operate recovery and


recycle machine
Detach evaporator air
filter
Fix evaporator air
filter
Detach cooling unit
assembly
Inspect expansion
valve function ability
Inspect thermostat
function ability
Assemble cooling unit
components
Fix cooling unit
assembly
Pack insulator to
cooling unit
Vacuum airconditioning system
Top up refrigerant oil
in air-conditioning
system
Charge refrigerant in
air-conditioning
system

STEPS

KNOWLEDGE

PERFORMANCE

HRS

DELIVERY
MODE

Attitude/Safety:
Meticulous when
adjusting belt tension

5. Discharge
refrigerant from airconditioning system

5.1 Environmental Rules and


Regulations of airconditioning system
5.2 Types of air-conditioning
refrigerant
5.3 Procedures of operating
recovery and recycle
machine
5.4 Types of high and low
pressure and colour code
5.5 Techniques of recovering
air-conditioning refrigerant
5.1 Interpret Environmental
Rules and Regulations
of air-conditioning
system
5.2 Determine types of airconditioning refrigerant
5.3 Set up recovery and
recycle machine in airconditioning system
5.4 Operate recovery and
recycle machine

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Lecture

Demonstration and
Observation

ASSESSMENT MODE

STEPS

KNOWLEDGE

PERFORMANCE
Attitude/Safety:
Comply with
environmental act
Handle equipment and
special tools with care

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HRS

DELIVERY
MODE

ASSESSMENT MODE

STEPS

KNOWLEDGE

6. Remove evaporator
air filter

6.1 Function of evaporator air


filter
6.2 Operation of evaporator air
Filter
6.3 Procedures of removing
evaporator air filter
6.4 Techniques of removing
evaporator air filter

PERFORMANCE

6.1 Locate position of


evaporator air filter
6.2 Detach evaporator air
filter
Attitude/Safety:
Meticulous when
removing evaporator air
filter

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HRS

DELIVERY
MODE

Lecture

Demonstration and
Observation

ASSESSMENT MODE

STEPS
7.

Install evaporator
air filter

KNOWLEDGE

PERFORMANCE

7.1 Procedures of installing


evaporator air filter
7.2 Techniques of installing
evaporator air filter
7.1 Fix evaporator air filter

HRS

DELIVERY
MODE

Lecture

Demonstration and
Observation

Attitude/Safety:
Meticulous when fixing
evaporator air filter

8.

Remove cooling
unit assembly

8.1 Function of cooling unit


assembly
8.2 Operation cooling unit
assembly
8.3 Procedures of removing
cooling unit assembly
8.4 Techniques of removing
cooling unit assembly

2
Lecture

8.1 Locate position of


cooling unit assembly
8.2 Detach cooling unit
assembly
Attitude/Safety:
Meticulous when
removing cooling unit
assembly

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Demonstration and
Observation

ASSESSMENT MODE

STEPS
9. Check cooling unit
components

KNOWLEDGE

PERFORMANCE

9.1 Function of expansion


valve
9.2 Function of thermostat
9.3 Method of checking
expansion valve function
ability
9.4 Method of checking
thermostat function ability
9.1 Inspect expansion valve
function ability
9.2 Inspect thermostat
function ability

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HRS

DELIVERY
MODE

Lecture

Demonstration and
Observation

ASSESSMENT MODE

STEPS

KNOWLEDGE

10. Install cooling unit


assembly

10.1 Techniques of assembling


cooling unit components
10.2 Techniques of installing
cooling unit
10.3 Types of insulator

PERFORMANCE

10.1 Assemble cooling unit


Components
10.2 Fix cooling unit
assembly
10.3 Pack insulator to
cooling unit
Attitude/Safety:
Meticulous when fixing
cooling unit assembly

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HRS

DELIVERY
MODE

Lecture

Demonstration and
Observation

ASSESSMENT MODE

STEPS
11. Recharge
refrigerant in airconditioning
system

KNOWLEDGE

PERFORMANCE

11.1 Volume of refrigerant


required for airconditioning system
11.2 Procedures of vacuuming
and charging
11.3 Types, function, and
quantity of refrigerant oil
11.1 Vacuum air-conditioning
system
11.2 Top up refrigerant oil in
air-conditioning system
11.3 Ensure recommended
quantity of refrigerant
oil is filled in airconditioning system
11.4 Charge refrigerant in
air-conditioning system
Attitude/Safety:
Comply with
environmental act
Wear personal
protection equipment
Handle equipment and
special tools with care

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HRS

DELIVERY
MODE

Lecture

Demonstration and
Observation

ASSESSMENT MODE

Core Abilities
01.04 Analyze information
01.05 Utilize the internet to locate and gather information
01.06 Utilize word processor to process information
04.01 Organize own work activities
04.04 Apply problem solving strategies
NOTE ON ASSESSMENT MODE:
A : Practical; B : Project; C : Oral; D : Written; E : Others

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Selected References and Audio Visual Materials


REFERENCES
1. Anthony E.Schwaller (2004) Total Automotive Technology, 4th
Edition-Delmar Learning, New York USA, ISBN: 1-4018-2476-5

AUDIO VISUAL MATERIALS

2. Ed May (2003) Automotive Mechanic Vol 2 7th Edition, Mc GrawHill Australia ISBN: 0074712969
3. Boyce H. Dwiggins (2001) Automotive Air-Conditioning, Cengage
Learning, ISBN:13-9780766807884, 978-0766807884

Tools, Equipment Supplies and Facilities


ITEMS
1. Hand tools set
2. Special tools
3. Air-conditioning belt
4. Belt tensioner assembly
5. Air-conditioner service manual
6. Fender cover
7. Lubricant/grease
8. Replacement parts
9. Wheel stopper
10. Safety stands
11. Personal protection equipment
12. Recovery and recycle machine
13. Refrigerant oil
14. Environmental act

RATIO (Equipment : Trainees)


1:5
1:5
1:5
1:5
1:5
1:5
As per required
As per required
1:5
As per required
1: 1
1:25
As per required
1:5

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