This document is from a Toyota training course on air conditioning and climate control systems. It covers the basic components and functions of automotive air conditioning systems, including compressors, condensers, evaporators, expansion valves, and controls. It also discusses diagnosing and repairing AC systems, such as checking pressures and using leak detectors to find issues. The document uses diagrams and images to illustrate the components and cycling of refrigerant through the AC system.

1. A/C SYSTEM

2. AIR CONDITIONING & CLIMATE CONTROL

3. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 3
VAPORIZATION
PAGE 2-1

4. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 5
Hot and Cold
a. Hot attracted to cold – heat flows from hot
area to cooler area.
b. Removal of Heat (not really cooling), lowers
temperature.
HEAT TRANSFER HOT TO COLD

5. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 6PAGE 2-6
REFRIGERATE CIRCUIT

6. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 7
SOURCES OF HEAT IN A
PASSENGER CAR

7. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 8
2-WAY AIRFLOW
Fresh, dry external air to the upper area
Warm internal air to the footwell area
External Air

8. A/C SYSTEM COMPONENTS
TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL

9. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 10
BASIC COMPONENTS
PAGE 3-1

10. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 11
SWASH-PLATE COMPRESSOR
PAGE 3-5
Show Animation

11. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 12
PISTON-TYPE A/C COMPRESSOR
PAGE 3-6
Suction Discharge
Down-Stroke Up-Stroke

12. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 13
THROUGH-VANE COMPRESSOR
PAGE 3-6
Discharge Valve
Exhaust Port
Rotor
Sludging Valve
Valve
Rotor Housing
Intake Port
Through-Vane
Discharge Reed Valve

13. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 14
SCROLL COMPRESSOR CYCLE
PAGE 3-10
Compression
Discharge
Port
Discharge
Suction
Variable
Scroll
Fixed
Scroll
Intake
Port

14. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 15
COMPRESSOR CLUTCH
PAGE 3-11
Rotor
Stator Coil
Bearing
Stator
Pressure Plate

15. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 16
DAMPER LIMITER PULLEY
Spoke
Portions
DamperLimiter Mechanism
PAGE 3-12

16. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 17
CONDENSER
PAGE 3-14

17. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 18
RECEIVER-DRIER
Sight Glass
Receiver Tube
Receiver Body Filter
Desiccant
Drier
OUT
IN
PAGE 3-15

18. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 19
SIGHT GLASS
Receiver-Drier
Sight Glass
Insufficiently
Charges
Properly
Charges
PAGE 4-2

19. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 21
EXPANSION VALVE
PAGE 3-1
Valve
Pressure
Spring
Diaphragm
Diaphragm Chamber
Outlet
Capillary Tube
Equalizer Circuit
(For Internal Equalizer Type)
Heat-
Sensing
Tube
Inlet

20. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 22
BLOCK TYPE EXPANSION VALVE
PAGE 3-2
Valve

21. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 23
ORIFICE TYPE EXPANSION VALVE
PAGE 3-2

22. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 24
ORIFICE TYPE EXPANSION VALVE
PAGE 3-2

23. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 25
EVAPORATOR
PAGE 3-3

24. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 26
THREAD TYPE FITTINGS
HFC-134a CFC-12
PAGE 3-19

25. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 27
QUICK DISCONNECT FITTING
PAGE 3-20

26. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 28
MULTI-PRESSURE SWITCH
PAGE 3-18
Compressor
Clutch
Condenser Fan
(High Speed)
Source Voltage Source Voltage
Magnetic Clutch C ontrol
Low
Pressure
(NC)
Medium
Pressure
(NC) High
Pressure
(NC)

27. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 29
COOLING FANS
PAGE 3-21
Condenser Fans Engine Cooling Fan
Cooling Fan
Pulley Water
PumpFluid
Coupling

28. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 30
REVIEW BASIC A/C COMPONENTS

29. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 31
A/C REFRIGERANT CYCLE
PAGE 3-24

30. DIAGNOSIS AND REPAIR
TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL

31. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 33
1. 6-Step Diagnosis Procedure
1. Verify the complaint
2. Determine related symptoms
3. Analyze the symptom
4. Isolate the cause
5. Correct the cause
6. Check for proper operation
6-STEP DIAGNOSIS PROCEDURE

32. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 34
2. System Checks
1. Performance Test – Outlet temperature 35°F – 45°F
2. Check coolant level
3. Compressor belt tension
4. Click test – compressor drive
5. Outlet airflow checks (clean air filter[s])
6. Sight glass in high pressure line
7. Touch test: Low (cold), High (hot)
SYSTEM CHECKS

33. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 35
SIGHT GLASS
PAGE 4-2
Receiver-Drier
Sight Glass
Insufficiently
Charges
Properly
Charges

34. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 36
a. Visual inspection (stains)
b. Check system pressure
c. Recover refrigerant
d. Evacuate to remove moisture
e. Partial charge (to 50 psi), then check for leaks
f. Repair leaks as needed
g. Recharge system, check performance (including fan)
h. Remove debris/dirt from condenser
A/C SPECIFIC MAINTENANCE AND
INSPECTION

35. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 37
A/C PRESSURE GAUGE
PAGE 4-5

36. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 38
NORMAL SYSTEM PRESSURE
PAGE 4-6

37. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 39
ELECTRONIC LEAK DETECTOR
PAGE 4-8

38. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 40
FLUORESCENT DETECTION DYE
PAGE 4-8

39. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 41
FLUORESCENT DETECTION DYE
PAGE 4-8

40. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 42
REFRIGERANT IDENTIFIER
PAGE 4-10
Sample Exhaust Port;
On Rear of Case
Portable Case;
Bottom Half
Control Panel
Sample Inlet Port
System Pressure
Gauge
Sample Filter
Printer Port
Purge Vent Port
Air Intake Port
Power Cord

41. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 43
RECOVER/RECYCLE/RECHARGE
STATION
PAGE 4-7

42. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 44
R-134A PREVENTS
PENGUIN SUNBURN
PAGE 4-7

43. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 45
DRIVE BELT TENSION GAUGE
PAGE 4-11
Belt Tension Gauge
A/C Compressor
Crankshaft Pulley

44. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 46
AUTO DRIVE BELT TENSIONER
Automatic tensioner belt wear range:
A = “Normal” range
B = New belt range
PAGE 4-11

45. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 47
CLEARING CONDENSER DEBRIS
PAGE 4-14

46. A/C SYSTEM CONTROLS
TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL

47. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 49
TEMPERATURE CONTROL SYSTEM
PAGE 5-1

48. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 50
HEATER CONTROL VALVE
PAGE 5-1

49. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 51
CABLE-OPERATED HEATER
CONTROL VALVE
PAGE 5-2
OUT
IN
Rotary Valve

50. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 52
AIR MIX TEMPERATURE CONTROL
PAGE 5-3
Air Mix Control Damper
Heater Core

51. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 53
AIR MIX SERVO-MOTOR
PAGE 5-3

52. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 54
AIR MIX BLEND DOOR
PAGE 5-4
Evaporator
Blend Door
Heater Core

53. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 55
CLEAN AIR FILTER
PAGE 5-6
Clean Air Filter

54. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL
HEPA Filter and Fresh Air Inlet
56

55. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL
HVAC Housing and Ducting
57

56. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL
HVAC Housing and Ducting
58

57. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL
HVAC Housing and Ducting
59

58. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL
HVAC Housing and Ducting
60

59. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 61
A/C CONTROL PANEL
PAGE 5-7

60. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 62
CONTROL OF AIR DISTRIBUTION
SCHEMATIC
PAGE 5-7
Heater
Evaporator
Inlet
Blower Motor
FACE Vents

61. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 63
AIRFLOW THROUGH SYSTEM
PAGE 5-8

62. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL
Air Flow Ducting
64

63. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 65
AIR OUTLET/MODE CHART
PAGE 5-9

64. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL 66
REAR AIR CONDITIONING
PAGE 6-18

65. TOYOTA COURSE 752 – AIR CONDITIONING & CLIMATE CONTROL
End Heating and AC Systems
67