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 manufacture’s 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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 DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
Knowledge (D)
1. Identify air- 1.1 Purpose of air-conditioning 1 Lecture
conditioning system system Performance (A/C)
location 1.2 Types of air-conditioning  Air-conditioning
system components system component
1.3 Air- conditioning system location
component location  Detach air-
1.1 Determine air- 2 Demonstration and conditioning
conditioning system Observation belts from pulley
component location  Detach tensioner
assembly
Attitude/Safety:  Fix the air-
 Meticulous when conditioning
interpreting service tensioner assembly
manual and belt
 Adjust belt tension
2. Remove air- 2.1 Types of air-conditioning 1 Lecture according to
conditioning belt belt specification
2.2 Procedures of removing air-  Tighten air-
conditioning belt conditioning
tensioner assembly to
2.1 Detach air-conditioning 2 Demonstration and specifications
belts from pulley Observation  Types of air-
2.2 Determine serviceability conditioning
of belt refrigerant
 Set up recovery and
Attitude/Safety: recycle machine in
 Use fender cover air-conditioning
system

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 DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
3. Remove air- 3.1 Tensioner assembly 2 Lecture  Operate recovery and
conditioning construction recycle machine
tensioner assembly 3.2 Types of air-conditioning  Detach evaporator air
tensioner filter
3.3 Types of air-conditioning  Fix evaporator air
pulley with bearing filter
 Detach cooling unit
3.1 Determine serviceability 3 Demonstration and assembly
tensioner assembly Observation  Inspect expansion
3.2 Detach tensioner valve function ability
assembly  Inspect thermostat
function ability
Attitude/Safety:
 Assemble cooling unit
 Meticulous when components
removing tensioner

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 DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
 Fix cooling unit
4. Install air- 4.1 Procedures of installing air- 1 Lecture assembly
conditioning conditioning tensioner
 Pack insulator to
tensioner assembly assembly and belt
cooling unit
and belt 4.2 Specifications of belt
 Vacuum air-
tension and tightening
conditioning system
torque 4.1 Fix the air-conditioning 3 Demonstration and
tensioner assembly and Observation  Top up refrigerant oil
belt in air-conditioning
4.2 Adjust belt tension system
according to  Charge refrigerant in
specification air-conditioning
4.3 Tighten air-conditioning system
tensioner assembly to
specifications

Attitude/Safety:
 Meticulous when
adjusting belt tension

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 DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE

5. Discharge 5.1 Environmental Rules and 2 Lecture

refrigerant from air- Regulations of air-
conditioning system conditioning 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 2 Demonstration and
Rules and Regulations Observation
of air-conditioning
system
5.2 Determine types of air-
conditioning refrigerant
5.3 Set up recovery and
recycle machine in air-
conditioning system
5.4 Operate recovery and
recycle machine

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 DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE

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

6. Remove evaporator 6.1 Function of evaporator air 1 Lecture

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

6.1 Locate position of 2 Demonstration and

evaporator air filter Observation
6.2 Detach evaporator air
filter

Attitude/Safety:
 Meticulous when
removing evaporator air
filter

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 DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE

7. Install evaporator 7.1 Procedures of installing 1 Lecture

air filter evaporator air filter
7.2 Techniques of installing
evaporator air filter

7.1 Fix evaporator air filter 2 Demonstration and

Observation
Attitude/Safety:
 Meticulous when fixing
evaporator air filter

8. Remove cooling 8.1 Function of cooling unit 2

unit assembly assembly Lecture
8.2 Operation cooling unit
assembly
8.3 Procedures of removing
cooling unit assembly
8.4 Techniques of removing
cooling unit assembly
8.1 Locate position of
cooling unit assembly 3 Demonstration and
8.2 Detach cooling unit Observation
assembly

Attitude/Safety:
 Meticulous when
removing cooling unit
assembly

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 DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE

9. Check cooling unit 9.1 Function of expansion 1 Lecture

components 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 2 Demonstration and

function ability Observation
9.2 Inspect thermostat
function ability

10. Install cooling unit 10.1 Techniques of assembling 1 Lecture

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

10.1 Assemble cooling unit 2 Demonstration and

Components Observation
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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 DELIVERY
STEPS KNOWLEDGE PERFORMANCE HRS ASSESSMENT MODE
MODE
11. Recharge 11.1 Volume of refrigerant 1 Lecture
refrigerant in air- required for air-
conditioning conditioning system
system 11.2 Procedures of vacuuming
and charging
11.3 Types, function, and
quantity of refrigerant oil

11.1 Vacuum air-conditioning 2 Demonstration and

system Observation
11.2 Top up refrigerant oil in
air-conditioning system
11.3 Ensure recommended
quantity of refrigerant
oil is filled in air-
conditioning 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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 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 AUDIO VISUAL MATERIALS
1. Anthony E.Schwaller (2004) Total Automotive Technology, 4th
Edition-Delmar Learning, New York USA, ISBN: 1-4018-2476-5

2. Ed May (2003) Automotive Mechanic Vol 2 7th Edition, Mc Graw-

Hill Australia ISBN: 0074712969

3. Boyce H. Dwiggins (2001) Automotive Air-Conditioning, Cengage

Learning, ISBN:13-9780766807884, 978-0766807884

Tools, Equipment Supplies and Facilities

ITEMS RATIO (Equipment : Trainees)
1. Hand tools set
1:5
2. Special tools
1:5
3. Air-conditioning belt
1:5
4. Belt tensioner assembly
1:5
5. Air-conditioner service manual
1:5
6. Fender cover
1:5
7. Lubricant/grease
As per required
8. Replacement parts
As per required
9. Wheel stopper
1:5
10. Safety stands
As per required
11. Personal protection equipment
1: 1
12. Recovery and recycle machine
1:25
13. Refrigerant oil
As per required
14. Environmental act
1:5

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