Department of Mechanical Engineering

Course File

Subject Automotive Air Conditioning(D082711(082))

Branch Automobile Engineering

Semester 7th

Year 2023-24

Dr. Sanjay G Sakharwade Faculty : Sameer Singh

HOD Asst. Professor
Dept. of Mechanical Engineering Dept. of Mechanical Engineering
RCET, Bhilai RCET, Bhilai
Mo. No- 7000185224
Email id - [email protected]

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 Course File Content

S. No. Topic Pg No.

1. First page 1

2. Vision & mission of the institute 3

3. Vision & mission of the department 3

4. Syllabus 4

5. Programme Outcomes 5

6. Course’s Outcomes 5

7 Mapping of Programme’s outcomes and Course’s Outcomes 6-7

8. Teaching Plan 8-9

9. Lecture plan & Notes Brief 10-24

10. Question Bank 25-29

11. Previous Year Question Papers 30-31

12. Assignments(I-V) 32-34

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 Vision & Mission of Institute

Vision
To be recognized among top ranking institutions in the country by 2025 that provides quality
education, pursuance of research and innovation.

Mission
To produce qualified and competent graduates to serve humanity by providing an environment
for holistic development through excellence in education and inculcating ethical values and
sense of social and environmental responsibilities. The institution is committed to disseminate
and preserve knowledge by stimulating intellectual growth through research and innovation.

Vision & Mission of Department

Vision
Globally recognized leader in Mechanical Engineering for excellence in teaching, innovative
research and technology development with societal impact Mission.

Mission
Prepare leaders of tomorrow bestowed with sound fundamentals, strategic thinking and global
awareness. Foster an environment of innovation and high-impact research addressing
real-world problems and catering the needs of the under-served.

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 Syllabus

UNIT I AIR CONDITIONING FUNDAMENTALS

Basic air conditioning system - Location of air conditioning components in a car -

Schematic layout of a refrigeration system. Compressor components - Condenser
and high pressure service ports. Thermostatic expansion valve – Expansion valve
calibration- Controlling evaporator temperature- Evaporator pressure regulator
–Evaporator temperature regulator.

UNIT II AIR CONDITIONER-HEATING SYSTEM

Automotive heaters - Manually controlled air conditioner - Heater system - Ford

automatically controlled air conditioner and heater systems-Automatic
temperature control-Air conditioning protection–Engine protection.

UNIT III REFRIGERANTS

Classification, Nomenclature, selection of Refrigerants, global warming potential

of CFC Refrigerants.

REFRIGERATION EQUIPMENTS

Compressor, condenser, evaporator ,expansion devices– types & working.

UNIT IV AIR ROUTING & TEMPERATURE CONTROL

Objectives - Evaporator care airflow through the Dash recirculation unit -

Automatic temperature control – Duct system- Controlling flow-Vacuum
reserve-Testing the air control and handling systems.

UNIT V TROUBLESHOOTING AND SERVICE

Causes of air conditioner failure - Troubleshooting of air controlling system - Air

conditioner maintenance and service-Servicing heater system. Removing and
replacing components–leak testing –Compressor service.

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 Programme Outcomes (PO’s)
1. An ability to apply knowledge of mathematics, basic sciences, and engineering as
applicable to the fields of Mechanical Engineering.
2. An ability to design and conduct experiments, as well as to organize, analyze, and
interpret data in the fields of mechanical Engineering.
3. An ability to design and construct mechanisms, machines, components and processes to
meet desired requirements, within realistic constraints such as economic, environmental,
social, political and ethical issues.
4. An ability to function on multidisciplinary and culturally diversified teams.
5. An ability to identify, formulate, and solve the problems using sound Mechanical
Engineering principles.
6. An understanding of professional and legal issues and responsibilities as it pertains to
Mechanical Engineering.
7. An ability to effectively communicate technical information in speech, presentation, and
in writing.
8. The broad education necessary to understand the impact of computing in a global,
economic, environmental, and public context.
9. Recognition of the need for an ability to engage in lifelong learning to cope-up with
rapidly changing technology.
10. Knowledge of contemporary developments.

Course’s Outcomes
Once the student has successfully complete this course, he/she will be able to answer
the following questions or perform following activities:

a) An ability to apply knowledge of Automotive Air Conditioning as applicable to the fields of

Mechanical Engineering.

b) An ability to design and conduct experiments, as well as to organize, analyzes, and interprets
data in the fields of Automotive Air conditioning.

c) An ability to design and construct mechanisms, machines, components and processes to meet
desired requirements, within realistic constraints such as economic, environmental, social,
political and ethical issues.

d) An ability to function on multidisciplinary and culturally diversified teams.

e) An ability to identify, formulate, and solve the problems using Automotive Air Conditioning
principles.

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 Mapping of Course’s Outcomes with Programme Outcome

CO: An ability to apply knowledge of Automotive Air Conditioning as applicable to the

fields of Mechanical Engineering.

● Mapped to PO1: An ability to apply knowledge of mathematics, basic sciences, and

engineering as applicable to the fields of Mechanical Engineering.
○ Justification: Applying knowledge of Automotive Air Conditioning requires a
solid foundation in mechanical engineering principles, which include
mathematics, basic sciences, and engineering. This CO directly supports the
ability to utilize and integrate these foundational principles into specific
applications like automotive air conditioning.

CO: An ability to design and conduct experiments, as well as to organize, analyze, and
interpret data in the fields of Automotive Air Conditioning.

● Mapped to PO2: An ability to design and conduct experiments, as well as to organize,

analyze, and interpret data in the fields of Mechanical Engineering.
○ Justification: Designing and conducting experiments, along with data analysis
and interpretation in automotive air conditioning, is a specific application of
broader experimental skills in mechanical engineering. This CO supports the
development of these critical experimental and analytical skills.

CO: An ability to design and construct mechanisms, machines, components, and

processes to meet desired requirements, within realistic constraints such as economic,
environmental, social, political, and ethical issues.

● Mapped to PO3: An ability to design and construct mechanisms, machines,

components, and processes to meet desired requirements, within realistic constraints
such as economic, environmental, social, political, and ethical issues.
○ Justification: This CO and PO are directly aligned, as both involve the design
and construction of engineering solutions while considering various realistic
constraints. The skills and knowledge gained from this CO directly contribute to
the broader goal of creating feasible and responsible engineering designs.

CO: An ability to function on multidisciplinary and culturally diversified teams.

● Mapped to PO4: An ability to function on multidisciplinary and culturally diversified

teams.
○ Justification: Teamwork in a multidisciplinary and culturally diverse environment
is essential for modern engineering projects. This CO supports the development
of collaboration and communication skills necessary for effective teamwork,
aligning directly with this PO.

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CO: An ability to identify, formulate, and solve the problems using Automotive Air
Conditioning principles.

● Mapped to PO5: An ability to identify, formulate, and solve the problems using sound
Mechanical Engineering principles.
○ Justification: Identifying, formulating, and solving problems specific to
automotive air conditioning requires the application of broader mechanical
engineering principles. This CO enhances problem-solving skills that are crucial
across various mechanical engineering domains.

COs Related to Broader Mechanical Engineering Skills:

● Mapped to PO6: An understanding of professional and legal issues and responsibilities

as it pertains to Mechanical Engineering.
○ Justification: Professional and legal issues are important for all mechanical
engineering areas, including automotive air conditioning, ensuring that engineers
understand their responsibilities and ethical considerations.
● Mapped to PO7: An ability to effectively communicate technical information in speech,
presentation, and in writing.
○ Justification: Effective communication is essential for all engineers, including
those specializing in automotive air conditioning, to convey technical information
clearly and persuasively.
● Mapped to PO8: The broad education necessary to understand the impact of computing
in a global, economic, environmental, and public context.
○ Justification: A broad understanding of the global context helps engineers
appreciate the broader impact of their work, including environmental and public
implications of automotive air conditioning systems.
● Mapped to PO9: Recognition of the need for and an ability to engage in lifelong learning
to cope with rapidly changing technology.
○ Justification: Lifelong learning is crucial for staying current with technological
advancements, which is vital for all engineering fields, including automotive air
conditioning.
● Mapped to PO10: Knowledge of contemporary developments.
○ Justification: Keeping up with contemporary developments is essential for
innovation and maintaining relevance in the field of automotive air conditioning,
as well as broader mechanical engineering.

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 Teaching plan

S.No. Lecture Date of Topic

No. Delivery

UNIT I : AIR CONDITIONING FUNDAMENTALS(10 Lectures)

1. 1. Introduction to Air Conditioning Systems

2 2 Components of Air Conditioning Systems

3 3 Schematic Layout of a refrigeration system

4 4 Compressor Components

5 5 Condenser and High-Pressure Service Ports

6 6 Thermostatic Expansion Valve

7 7 Techniques to Controlling Evaporator Temperature

8 8 Evaporator Pressure Regulator

9 9 Evaporator Temperature Regulator

10 10 Review and Q&A Session for UNIT I

UNIT II : AIR CONDITIONER-HEATING SYSTEM(8 Lectures)

11 11 Automotive Heaters

12 12 Manually Controlled Air Conditioner

13 13 Heater System

14 14 Ford Automatically Controlled Air Conditioner

15 15 Automatic Temperature Control

16 16 Air Conditioning Protection

17 17 Engine Protection

18 18 Review and Q&A Session for UNIT II

UNIT III :REFRIGERANTS & REFRIGERATION EQUIPMENTS (8 Lecutres)

19 19 Classification of Refrigerants

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20 20 Nomenclature and Selection of Refrigerants

21 21 Global Warming Potential of CFC Refrigerants

22 22 Refrigeration Equipment: Compressors

23 23 Refrigeration Equipment: Condensers

24 24 Refrigeration Equipment: Evaporators

25 25 Refrigeration Equipment: Expansion Devices

26 26 Review and Q&A Session for UNIT III

UNIT IV :AIR ROUTING & TEMPERATURE CONTROL (7 Lectures)

27 27 Objectives of Air Routing

28 28 Automatic Temperature Control

29 29 Duct System

30 30 Controlling Airflow

31 31 Vacuum Reserve

32 32 Testing Air Control and Handling Systems

33 33 Review, Q&A, and Course Summary

UNIT V :TROUBLESHOOTING AND SERVICE (7 Lectures)

34 34 Causes of Air Conditioner Failure

35 35 Troubleshooting Air Controlling System

36 36 Air Conditioner Maintenance and Service

37 37 Servicing Heater System

38 38 Removing and Replacing Components

39 39 Leak Testing and Compressor Service

40 40 Review, Q&A, and Course Summary

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 Unit Wise Lecture Notes
UNIT I: AIR CONDITIONING FUNDAMENTALS

Lecture 1: Introduction to Air Conditioning Systems

Overview:

● Introduction to the importance of automotive air conditioning systems.

● Objectives of learning automotive air conditioning.

Topics Covered:

1. Basic Air Conditioning System:

○ Definition and purpose.
Air conditioning is the controlling of air temperature, its humidity, its purity,
noise free and its flow rate at a certain place to produce a comfort zone.
○ Overview of the components: Compressor, Condenser, Evaporator, Expansion
Valve, and Refrigerant.
○ Basic working principle of air conditioning systems.

2. Course Structure:
○ Overview of the syllabus and what to expect in the upcoming lectures.

Notes:

● An air conditioning system maintains the comfort of the car's interior by controlling the
temperature, humidity, and air quality.
● Key components and their functions:
○ Compressor: Pressurizes the refrigerant and circulates it through the system.
○ Condenser: Releases heat from the refrigerant to the outside air.
○ Evaporator: Absorbs heat from the car interior, cooling the air.
○ Expansion Valve: Controls the flow of refrigerant into the evaporator.

Lecture 2: Components of Air Conditioning Systems

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Overview:

● Detailed discussion on the location and function of air conditioning components in a car.

Topics Covered:

1. Location of Components:
○ Placement of the compressor, condenser, evaporator, and expansion valve within
the vehicle.
○ Importance of component placement for efficient operation.
2. Function of Each Component:
○ Role of each component in the overall system.

Notes:

● Compressor: Typically located at the front of the engine, driven by the engine's
crankshaft via a belt.
● Condenser: Located in front of the radiator, uses the airflow to cool the refrigerant.
● Evaporator: Placed inside the dashboard, connected to the air ducts.
● Expansion Valve: Located between the condenser and evaporator, controlling
refrigerant flow.

Lecture 3: Schematic Layout

Overview:

● Understanding the flow of refrigerant through the system and the schematic layout of an
automotive air conditioning system.

Topics Covered:

1. Schematic Diagram:
○ Drawing and interpretation of a basic air conditioning system schematic.
○ Flow of refrigerant and the role of each component in the cycle.

Notes:

● The refrigerant cycle:

1. Compressor: Compresses the refrigerant gas, increasing its pressure and
temperature.
2. Condenser: The high-pressure refrigerant gas is cooled and condensed into a
liquid.
3. Expansion Valve: The liquid refrigerant is expanded, lowering its pressure and
temperature.
4. Evaporator: The low-pressure refrigerant absorbs heat from the cabin, cooling
the air inside the car.

Lecture 4: Compressor Components

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Overview:

● In-depth look at the compressor, its components, and its function.

Topics Covered:

1. Compressor Components:
○ Piston, cylinder, crankshaft, valves, and clutch assembly.
○ Types of compressors: reciprocating, rotary, and scroll.

Notes:

● Reciprocating Compressors: Use a piston to compress refrigerant, common in older

systems.
● Rotary Compressors: Use rotating elements to compress refrigerant, more efficient and
compact.
● Scroll Compressors: Use interleaved scrolls to compress refrigerant, very efficient and
reliable.

Lecture 5: Condenser and High-Pressure Service Ports

Overview:

● Detailed study of the condenser and high-pressure service ports.

Topics Covered:

1. Condenser:
○ Types and functions.
○ Heat exchange process and factors affecting its efficiency.
2. High-Pressure Service Ports:
○ Location and purpose.
○ How to safely access and use service ports.

Notes:

● Condenser Types: Tube-and-fin, plate-and-fin, and serpentine.

● Service Ports: Provide access points for system charging and pressure monitoring.

Lecture 6: Thermostatic Expansion Valve

Overview:

● Understanding the role and calibration of the thermostatic expansion valve.

Topics Covered:

1. Expansion Valve Function:

○ Controls the amount of refrigerant entering the evaporator.
○ Responds to temperature and pressure changes.

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 2. Calibration:
○ Adjusting the valve to ensure optimal performance.
○ Factors influencing calibration.

Notes:

● Thermostatic Expansion Valve (TXV): Maintains the right amount of refrigerant flow,
preventing the evaporator from freezing.

Lecture 7: Controlling Evaporator Temperature

Overview:

● Techniques for maintaining optimal evaporator temperature.

Topics Covered:

1. Temperature Control Mechanisms:

○ Use of thermostats and pressure switches.
○ Role of the evaporator temperature sensor.

Notes:

● Thermostats: Control the compressor clutch, turning it on/off to maintain the desired
temperature.
● Pressure Switches: Monitor refrigerant pressure, ensuring it stays within safe limits.

Lecture 8: Evaporator Pressure Regulator

Overview:

● Function and importance of the evaporator pressure regulator.

Topics Covered:

1. Pressure Regulation:
○ Maintaining proper pressure in the evaporator.
○ Impact on system performance and efficiency.

Notes:

● Evaporator Pressure Regulator: Prevents evaporator pressure from dropping too low,
avoiding icing and ensuring efficient heat exchange.

Lecture 9: Evaporator Temperature Regulator

Overview:

● Mechanisms and importance of regulating evaporator temperature.

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Topics Covered:

1. Temperature Regulation:
○ Use of sensors and control units.
○ Impact on air conditioning performance.

Notes:

● Temperature Sensors: Provide feedback to control units, adjusting the compressor

operation to maintain desired temperatures.

Lecture 10: Review and Q&A Session for UNIT I

Overview:

● Recap of key concepts and a Q&A session to address any queries.

Topics Covered:

1. Review of UNIT I:
○ Summary of key points from lectures 1-9.
2. Q&A Session:
○ Addressing student questions and clarifying doubts.

Notes:

● Review: Reinforce understanding of air conditioning fundamentals and components.

● Q&A: Encourage student interaction and clarify any lingering questions.

UNIT II: AIR CONDITIONER-HEATING SYSTEM

Lecture 11: Automotive Heaters

Overview:

● Understanding the role and types of automotive heaters.

Topics Covered:

1. Heater Functions:
○ Purpose of automotive heaters.
○ Different types of heaters used in vehicles.

Notes:

● Automotive Heaters: Provide warmth to the cabin, enhancing passenger comfort during
cold weather.

Lecture 12: Manually Controlled Air Conditioner

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Overview:

● Detailed look at manually controlled air conditioning systems.

Topics Covered:

1. Manual Control Systems:

○ Components and operation.
○ Advantages and limitations.

Notes:

● Manual Systems: Require user input to adjust temperature and airflow, simple and
cost-effective.

Lecture 13: Heater System

Overview:

● Understanding the detailed workings of the heater system.

Topics Covered:

1. Heater Components:
○ Core, blower motor, and control system.
○ Integration with the vehicle's cooling system.

Notes:

● Heater Core: Acts like a small radiator, using engine coolant to heat the air that is blown
into the cabin.

Lecture 14: Ford Automatically Controlled Air Conditioner

Overview:

● Case study of Ford's automatically controlled air conditioning systems.

Topics Covered:

1. Automatic Systems:
○ Components and operation.
○ Advantages and advanced features.

Notes:

● Ford Systems: Use sensors and control units to automatically maintain desired cabin
temperature.

Lecture 15: Automatic Temperature Control

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Overview:

● Principles and mechanisms of automatic temperature control.

Topics Covered:

1. Automatic Control:
○ Use of sensors, control units, and actuators.
○ Maintaining consistent cabin temperature.

Notes:

● Sensors: Detect cabin and outside temperatures, adjusting system operation for optimal
comfort.

Lecture 16: Air Conditioning Protection

Overview:

● Mechanisms for protecting the air conditioning system.

Topics Covered:

1. Protection Mechanisms:
○ High-pressure cut-off switches, thermal fuses, and pressure relief valves.

Notes:

● High-Pressure Cut-Off Switch: Prevents system damage by shutting down the

compressor if pressure becomes too high.

Lecture 17: Engine Protection

Overview:

● Integration of air conditioning and engine protection mechanisms.

Topics Covered:

1. Engine Protection:
○ Methods to protect the engine from overheating due to air conditioning load.

Notes:

● Cooling Fans: Automatically activated to increase airflow through the radiator and
condenser when the air conditioning is on.

Lecture 18: Review and Q&A Session for UNIT II

Overview:

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 ● Recap of key concepts and a Q&A session to address any queries.

Topics Covered:

1. Review of UNIT II:

○ Summary of key points from lectures 11-17.
2. Q&A Session:
○ Addressing student questions and clarifying doubts.

Notes:

● Review: Reinforce understanding of air conditioner-heating systems and protection

mechanisms.
● Q&A: Encourage student interaction and clarify any lingering questions.

UNIT III: REFRIGERANTS & REFRIGERATION EQUIPMENTS

Lecture 19: Classification of Refrigerants

Overview:

● Types and classifications of refrigerants used in automotive air conditioning.

Topics Covered:

1. Refrigerant Types:
○ CFCs, HCFCs, HFCs, and natural refrigerants.
○ Characteristics and applications.

Notes:

● CFCs (Chlorofluorocarbons): High ozone depletion potential, now phased out.

● HCFCs (Hydrochlorofluorocarbons): Lower ozone depletion potential, transitional
refrigerants.
● HFCs (Hydrofluorocarbons): No ozone depletion potential, but high global warming
potential.
● Natural Refrigerants: Include hydrocarbons, CO2, and ammonia, eco-friendly options.

Lecture 20: Nomenclature and Selection of Refrigerants

Overview:

● Understanding the naming conventions and criteria for selecting refrigerants.

Topics Covered:

1. Nomenclature:
○ ASHRAE numbering system for refrigerants.
2. Selection Criteria:

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 ○ Environmental impact, efficiency, safety, and compatibility with system
components.

Notes:

● ASHRAE System: Uses a systematic code (e.g., R-134a) to identify refrigerants based
on their chemical composition.

Lecture 21: Global Warming Potential of CFC Refrigerants

Overview:

● Environmental impact of CFC refrigerants and their global warming potential.

Topics Covered:

1. CFC Impact:
○ Ozone depletion and global warming.
○ Regulations and phase-out timelines.

Notes:

● CFCs: Have a high global warming potential (GWP) and contribute significantly to
climate change, leading to their phase-out under international agreements like the
Montreal Protocol.

Lecture 22: Refrigeration Equipment: Compressors

Overview:

● Types and working principles of compressors used in automotive air conditioning.

Topics Covered:

1. Compressor Types:
○ Reciprocating, rotary, and scroll compressors.
2. Working Principles:
○ How each type of compressor operates and its advantages.

Notes:

● Reciprocating Compressors: Use pistons to compress refrigerant.

● Rotary Compressors: Use rotating elements for compression, more compact.
● Scroll Compressors: Use interleaved scrolls for compression, highly efficient.

Lecture 23: Refrigeration Equipment: Condensers

Overview:

● Types and working principles of condensers used in automotive air conditioning.

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Topics Covered:

1. Condenser Types:
○ Tube-and-fin, plate-and-fin, and serpentine condensers.
2. Working Principles:
○ How condensers dissipate heat from the refrigerant.

Notes:

● Tube-and-Fin Condensers: Use tubes and fins to enhance heat transfer.

● Plate-and-Fin Condensers: More compact and efficient, used in modern systems.
● Serpentine Condensers: Single continuous tube, offering efficient heat exchange.

Lecture 24: Refrigeration Equipment: Evaporators

Overview:

● Types and working principles of evaporators used in automotive air conditioning.

Topics Covered:

1. Evaporator Types:
○ Tube-and-fin, plate-and-fin, and serpentine evaporators.
2. Working Principles:
○ How evaporators absorb heat from the cabin air.

Notes:

● Evaporators: Facilitate heat absorption, cooling the air that is blown into the cabin.

Lecture 25: Refrigeration Equipment: Expansion Devices

Overview:

● Types and working principles of expansion devices used in automotive air conditioning.

Topics Covered:

1. Expansion Device Types:

○ Thermostatic expansion valves (TXV), orifice tubes, and capillary tubes.
2. Working Principles:
○ How expansion devices regulate refrigerant flow into the evaporator.

Notes:

● TXV: Adjusts flow based on temperature feedback.

● Orifice Tube: Fixed orifice size, simple and cost-effective.
● Capillary Tube: Simple and reliable, used in smaller systems.

Lecture 26: Review and Q&A Session for UNIT III

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Overview:

● Recap of key concepts and a Q&A session to address any queries.

Topics Covered:

1. Review of UNIT III:

○ Summary of key points from lectures 19-25.
2. Q&A Session:
○ Addressing student questions and clarifying doubts.

Notes:

● Review: Reinforce understanding of refrigerants and refrigeration equipment.

● Q&A: Encourage student interaction and clarify any lingering questions.

UNIT IV: AIR ROUTING & TEMPERATURE CONTROL

Lecture 27: Objectives of Air Routing

Overview:

● Purpose and goals of air routing in automotive air conditioning systems.

Topics Covered:

1. Air Routing Objectives:

○ Ensuring even distribution of cooled air.
○ Minimizing energy consumption.

Notes:

● Even Distribution: Critical for passenger comfort and system efficiency.

Lecture 28: Evaporator Care and Airflow

Overview:

● Maintenance of evaporators and managing airflow through the system.

Topics Covered:

1. Evaporator Care:
○ Cleaning and maintaining evaporators.
○ Preventing clogs and corrosion.
2. Airflow Management:
○ Ensuring optimal airflow for efficient cooling.

Notes:

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 ● Maintenance: Regular cleaning prevents blockages and maintains efficiency.

Lecture 29: Automatic Temperature Control

Overview:

● Advanced temperature control techniques in automotive air conditioning.

Topics Covered:

1. Temperature Control Systems:

○ Automatic vs. manual control systems.
○ Role of sensors and control units.

Notes:

● Automatic Control: Uses sensors to adjust system operation, providing consistent

comfort.

Lecture 30: Duct System

Overview:

● Design and functioning of duct systems in automotive air conditioning.

Topics Covered:

1. Duct Design:
○ Layout and materials.
○ Factors affecting airflow and efficiency.

Notes:

● Design Considerations: Minimize bends and restrictions to enhance airflow.

Lecture 31: Controlling Airflow

Overview:

● Techniques for controlling airflow in the air conditioning system.

Topics Covered:

1. Airflow Control:
○ Use of dampers, actuators, and control units.
○ Balancing airflow for optimal cooling.

Notes:

● Dampers: Regulate the flow of air through different ducts, ensuring balanced cooling.

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Lecture 32: Vacuum Reserve

Overview:

● Function and importance of the vacuum reserve in air conditioning systems.

Topics Covered:

1. Vacuum Reserve:
○ How it supports the operation of air control systems.
○ Maintenance and troubleshooting.

Notes:

● Vacuum Systems: Provide power for controlling air doors and other components.

Lecture 33: Testing Air Control and Handling Systems

Overview:

● Methods and tools for testing air control and handling systems.

Topics Covered:

1. Testing Procedures:
○ Step-by-step guide to testing system components.
○ Identifying and diagnosing issues.

Notes:

● Testing Tools: Include pressure gauges, leak detectors, and flow meters.

UNIT V: TROUBLESHOOTING AND SERVICE

Lecture 34: Causes of Air Conditioner Failure

Overview:

● Common causes of air conditioner failure and how to prevent them.

Topics Covered:

1. Failure Causes:
○ Refrigerant leaks, component wear, electrical issues.

Notes:

● Prevention: Regular maintenance and inspections to catch issues early.

Lecture 35: Troubleshooting Air Controlling System

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Overview:

● Techniques and tools for troubleshooting air controlling systems.

Topics Covered:

1. Troubleshooting Steps:
○ Identifying symptoms, isolating problems, and implementing fixes.

Notes:

● Systematic Approach: Follow a logical process to diagnose and repair issues.

Lecture 36: Air Conditioner Maintenance and Service

Overview:

● Regular maintenance practices for air conditioning systems.

Topics Covered:

1. Maintenance Tasks:
○ Checking refrigerant levels, cleaning components, replacing filters.

Notes:

● Regular Checks: Ensure system longevity and efficiency.

Lecture 37: Servicing Heater System

Overview:

● Methods for servicing automotive heater systems.

Topics Covered:

1. Heater Service:
○ Flushing heater core, checking coolant levels, inspecting hoses.

Notes:

● Preventive Maintenance: Helps avoid major failures and ensures consistent heating.

Lecture 38: Removing and Replacing Components

Overview:

● Steps and precautions for removing and replacing air conditioning components.

Topics Covered:

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 1. Component Replacement:
○ Detailed procedure for safely removing and installing parts.

Notes:

● Safety First: Always follow manufacturer guidelines and safety protocols.

Lecture 39: Leak Testing and Compressor Service

Overview:

● Methods for leak testing and servicing compressors.

Topics Covered:

1. Leak Testing:
○ Using electronic leak detectors and dye tests.
2. Compressor Service:
○ Checking oil levels, inspecting for wear, and replacing faulty compressors.

Notes:

● Leak Detection: Critical for maintaining system efficiency and preventing refrigerant
loss.

Lecture 40: Final Review and Q&A Session

Overview:

● Comprehensive review of the entire course and a final Q&A session.

Topics Covered:

1. Course Review:
○ Summary of key concepts from all units.
2. Q&A Session:
○ Addressing final questions and preparing for assessments.

Notes:

● Final Review: Ensure thorough understanding of automotive air conditioning systems.

● Q&A: Encourage student interaction and clarify any remaining doubts

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 Question Bank
UNIT I: AIR CONDITIONING FUNDAMENTALS

4 Marks Questions

1. What is the basic principle of an automotive air conditioning system?

2. Define a refrigeration cycle and its relevance to automotive air conditioning.
3. Describe the function of a compressor in an automotive air conditioning system.
4. Explain the role of a condenser in the automotive air conditioning system.
5. What is the purpose of the evaporator in an air conditioning system?
6. Define thermostatic expansion valve and its function.
7. What is the significance of high-pressure service ports in an air conditioning system?
8. Describe the layout of a basic air conditioning system.
9. Explain the role of evaporator pressure regulators.
10. Define and explain the evaporator temperature regulator.
11. What are the key components of an automotive air conditioning system?
12. Describe the process of expansion valve calibration.
13. Explain the function of the evaporator in an air conditioning system.
14. What is the role of the compressor in maintaining the refrigerant cycle?
15. Describe the basic function of the refrigeration system in a car.

8 Marks Questions

1. Draw and explain the schematic layout of an automotive air conditioning system.
2. Discuss the components of the compressor and their functions.
3. Explain the working and control mechanisms of the thermostatic expansion valve.
4. Describe in detail the process of controlling evaporator temperature.
5. Explain the functions of evaporator pressure and temperature regulators.
6. Discuss the major components and their roles in an automotive air conditioning system.
7. Describe the process of refrigerant flow in an automotive air conditioning system.
8. Explain the steps involved in the maintenance of an air conditioning system.
9. Discuss the significance of evaporator care and maintenance.
10. Explain the role and function of high-pressure service ports.
11. Describe the process and importance of expansion valve calibration.
12. Explain the working principles of a refrigeration cycle in an automotive context.
13. Discuss the steps involved in the calibration of expansion valves.
14. Explain the process of maintaining optimal evaporator temperature.
15. Describe the components and working of a condenser in an automotive air conditioning
system.

UNIT II: AIR CONDITIONER-HEATING SYSTEM

4 Marks Questions

1. Define automotive air heater.

2. What is the purpose of a heating system in an automobile?

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 3. Explain the function of an automotive air conditioning heater.
4. Describe the manually controlled air conditioner system.
5. What is the function of a heater core in an automotive air conditioning unit?
6. Define automatic temperature control in automotive systems.
7. Describe the protection mechanisms for air conditioning systems.
8. What is the role of engine protection in automotive air conditioning?
9. Explain the basic operation of an automotive heater.
10. Describe the working of a manually controlled heater system.
11. What is the significance of automatic temperature control in air conditioning systems?
12. Explain the function of the Ford automatically controlled air conditioner system.
13. What are the components of an automatic temperature control system?
14. Describe the process of air conditioning protection in automotive systems.
15. Explain the role of heater systems in automotive air conditioning.

8 Marks Questions

1. Describe the components and working of the Ford automatically controlled air
conditioner and heater system.
2. Explain the steps involved in the automatic temperature control process in vehicles.
3. Discuss the various components of an automotive heating system and their functions.
4. Describe the manually controlled air conditioner and heater system in vehicles.
5. Explain the process and significance of air conditioning protection in automotive
systems.
6. Discuss the automatic temperature control system used in automotive air conditioning.
7. Describe the working of a heater core in an automotive air conditioning system.
8. Explain the differences between manual and automatic temperature control systems.
9. Describe the components and working of an automotive heating system.
10. Explain the process of engine protection in the context of automotive air conditioning.
11. Discuss the significance of heater systems in maintaining vehicle comfort.
12. Describe the steps involved in maintaining and servicing an automotive heater system.
13. Explain the role and function of automatic temperature control in modern vehicles.
14. Discuss the protection mechanisms for automotive air conditioning and heating systems.
15. Describe the working principles of manually controlled and automatically controlled air
conditioning systems.

UNIT III: REFRIGERANTS

4 Marks Questions

1. What is a refrigerant? Explain its role in automotive air conditioning systems.

2. Describe the classification of refrigerants used in automotive air conditioning.
3. What are CFC refrigerants and their impact on global warming?
4. Explain the criteria for selecting refrigerants for automotive air conditioning systems.
5. Describe the working of an expansion device in an automotive air conditioning system.
6. What is the role of a compressor in an automotive air conditioning system?
7. Explain the working of a condenser in an automotive air conditioning system.
8. Describe the types of evaporators used in automotive air conditioning systems.
9. What is the significance of refrigerant nomenclature?

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 10. Explain the global warming potential of different types of refrigerants.
11. What are the environmental impacts of refrigerants used in automotive air conditioning?
12. Describe the types and working of compressors used in automotive air conditioning.
13. What are the common refrigerants used in automotive air conditioning systems?
14. Explain the working principles of an expansion device.
15. Describe the process of refrigerant selection for automotive air conditioning systems.

8 Marks Questions

1. Discuss the classification and nomenclature of refrigerants used in automotive air

conditioning.
2. Explain the environmental impacts of CFC refrigerants and their alternatives.
3. Describe the working and types of compressors used in automotive air conditioning
systems.
4. Explain the working of expansion devices and their types used in automotive air
conditioning.
5. Discuss the construction and working of condensers in automotive air conditioning
systems.
6. Describe the global warming potential of different refrigerants and their environmental
impacts.
7. Explain the criteria for selecting refrigerants for automotive air conditioning systems.
8. Discuss the types and working of evaporators in automotive air conditioning systems.
9. Describe the process of refrigerant flow in an automotive air conditioning system.
10. Explain the significance of refrigerant nomenclature in automotive air conditioning.
11. Discuss the working principles of compressors used in automotive air conditioning.
12. Describe the construction and working of expansion devices in automotive air
conditioning systems.
13. Explain the role and function of condensers in automotive air conditioning systems.
14. Discuss the environmental impacts and global warming potential of different refrigerants.
15. Describe the process of selecting and using refrigerants in automotive air conditioning
systems.

UNIT IV: AIR ROUTING & TEMPERATURE CONTROL

4 Marks Questions

1. Define air routing and state its objectives in an automotive air conditioning system.
2. What is the role of automatic temperature control in vehicles?
3. Describe the components of the duct system used in automotive air conditioning.
4. Explain the significance of vacuum reserve in the air control system.
5. What are the objectives of air routing in an automotive air conditioning system?
6. Describe the airflow through the Dash recirculation unit.
7. Explain the methods of controlling airflow in an automotive air conditioning system.
8. What is the role of air ducts in automotive air conditioning systems?
9. Describe the process of testing air control and handling systems in vehicles.
10. Explain the function of the evaporator in air routing.
11. What are the components of an automatic temperature control system?
12. Describe the process of air routing in an automotive air conditioning system.

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 13. Explain the importance of vacuum reserve in maintaining air control.
14. Describe the objectives and functions of the duct system in automotive air conditioning.
15. What is the significance of air handling systems in vehicles?

8 Marks Questions

1. Explain the working of Automatic Temperature Control (ATC) systems in vehicles.

2. Describe the components and working of the duct system used in automotive air
conditioning.
3. Discuss the importance of vacuum reserve in the air control system of an automotive air
conditioning unit.
4. Explain the objectives and process of air routing in an automotive air conditioning
system.
5. Describe the airflow through the Dash recirculation unit and its significance.
6. Discuss the methods of controlling airflow in an automotive air conditioning system.
7. Explain the applications and importance of air ducts in automotive air conditioning
systems.
8. Describe the components and working of air handling systems in vehicles.
9. Discuss the significance and working of automatic temperature control systems.
10. Explain the role of the evaporator in air routing and temperature control.
11. Describe the process and significance of testing air control and handling systems in
vehicles.
12. Explain the working principles of automatic temperature control systems in automotive
air conditioning.
13. Discuss the components and functions of the duct system in an automotive air
conditioning system.
14. Describe the process and importance of maintaining vacuum reserve in air control
systems.
15. Explain the objectives and methods of air routing in automotive air conditioning systems.

UNIT V: TROUBLESHOOTING AND SERVICE

4 Marks Questions

1. What are the common causes of air conditioner failure in vehicles?

2. Describe the steps involved in checking for leaks in an automotive air conditioning
system.
3. Explain the process of troubleshooting an automotive air conditioning system.
4. What are the procedures for servicing and repairing an automotive heating system?
5. Describe the maintenance practices for ensuring the efficient operation of an automotive
air conditioning system.
6. What are the steps involved in removing and replacing components of an automotive air
conditioning system?

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 7. Explain the importance of compressor service in maintaining the automotive air
conditioning system.
8. What are the common troubleshooting steps for an air controlling system?
9. Explain the process of servicing heater systems in vehicles.

8 Marks Questions
1. Describe the steps involved in checking for leaks in an automotive air conditioning
system.
2. Explain the process of troubleshooting an automotive air conditioning system.
3. Discuss the procedures for servicing and repairing an automotive heating system.
4. Describe the steps involved in removing and replacing components of an automotive air
conditioning system.
5. Explain the importance of compressor service in maintaining the automotive air
conditioning system.
6. Discuss the methods used for leak testing in automotive air conditioning systems.

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Previous year Question Papers

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31
 Assignments

Assignment I(UNIT I)

Q1. Define an automotive air conditioning system.

Q2. Draw the layout of the refrigeration system used in automobiles and explain it.

Q3. Explain the working of the thermostatic expansion valve.

Q4. What do you understand about the high pressure and low pressure side of an
automotive air conditioning system?

Q5. What is the difference between refrigeration and air conditioning?

Q6. Draw the layout of the automotive air conditioning system.

Q7. Explain the evaporator and its location in the air conditioning system.

Q8. What are the 5 major components of an automobile air conditioning system.

Q9. Explain the functioning of Air conditioning system in an automobile with a neat sketch.

Q10. Explain the working of basic refrigeration system.

Assignment II(UNIT II)

Q1. Define automotive air heaters.

Q2. Explain the purpose of the heating system in an automobile and its working.

Q3. With the aid of a labelled sketch write the working of Ford automatically controlled
air conditioner and heater system.

Q4. What is the function of the heater core used in an automotive air conditioning?

Q5. How is the heater and radiator related in the air conditioning system?

Q6. Discuss the importance of heating systems in an automobile. Write the desirable
properties of an ideal heating system.

Q7. Discuss the working of heating system in an automobile

Q8. Explain automatically controlled air conditioners.

Q9. Discuss the difference between manual air conditioners and automated air
conditioners.

Q10. Explain the automotive air conditioning system used in automobiles with working of
its equipment.

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 Assignment III(UNIT III)

Q1. Define refrigerant and give properties of R-22

Q2. Explain global warming potential and role of refrigerant in the depletion of ozone
layer.

Q3. Explain the working of expansion devices and its type.

Q4. Write properties for a good refrigerant also categorized in terms of mechanical,
physical and chemical.

Q5. What is refrigerant? Write down its classification.

Q6. Explain how CFC refrigerant is responsible for global warming.

Q7. Explain about the compressor and classify it.

Q8. What is an expansion device? Write down its types and explain its working.

Q9. Explain the properties of any 3 refrigerants.

Q10. Draw neat sketch of compressor and expansion device and provide its working
details.

Assignment IV(UNIT IV)

Q1. Define air routing and state its objectives.

Q2. Explain the working of Automatic Temperature Control(ATC)

Q3. Explain briefly about the air handling system.

Q4. Write down the applications of duct in automotive air conditioning systems.

Q5. What are the requirements of a duct system for automotive air conditioning?

Q6. Explain the air flow in the heater enabled air conditioning system.

Q7. Explain the advantages and disadvantages of Automatic temperature control.

Q8. What do you mean by air handling system? Give flow diagram for air conditioning
system

Q9. Explain the working of the air handling system and air routing with neat sketches

Q10. Give working principle of Air flow in the heater of an air conditioning system

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 Assignment V(UNIT V)

Q1. Write cause of air conditioning failure.

Q2. Requirement of leak detection and explain any one leak detection method.

Q3. Describe the procedure for adding oil into the compressor.

Q4. Write problems occur in the air conditioning system and also provide solutions for
the same.

Q5. Explain air conditioning failure and also draw a neat diagram of the air conditioning
system.

Q6. What are the steps involved in checking the leakage from compressor removing
and replacing components.

Q7. How to troubleshoot the air conditioning system explained in detail.

Q8. How servicing and repairing of an automotive heating system is done?

Q9. Explain methods of leak testing in automotive air conditioning systems.

Q10. Explain the importance of compressor service in air conditioning systems.

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