By the end of this chapter, you will be able to:
Mastering these skills ensures you can confidently maintain and improve vehicle comfort and safety, making you a valuable technician in the automotive trade.
Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Manifold gauge set with charging hoses | Automobile air conditioning unit |
| Digital multimeter | Refrigerant cylinder R134a |
| Leak detector | Gloves |
| Thermometer with probe | Safety boots |
| Insulated screwdriver set | Overall/dust coat |
| Pliers |
| S/N | Item | Quantity |
|---|---|---|
| 1 | Automobile air conditioning unit (split type) | 1 Pc per Candidate |
| 2 | Manifold gauge set with charging hoses | 1 Set per Candidate |
| 3 | Refrigerant cylinder R134a | 1 Cylinder per 5 Candidates |
| 4 | Digital multimeter | 1 Pc per Candidate |
| 5 | Leak detector (electronic type) | 1 Pc per Candidate |
| 6 | Thermometer with probe | 1 Pc per Candidate |
| 7 | Insulated screwdriver set | 1 Set per Candidate |
| 8 | Pliers | 1 Pc per Candidate |
| 9 | Gloves | 1 Pair per Candidate |
| 10 | Safety boots | 1 Pair per Candidate |
| 11 | Overall/dust coat | 1 Pc per Candidate |
| 12 | Service manual for automobile AC system | 1 Pc per Station |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Identification and Explanation of AC Charging System Components | |||
| Wore appropriate PPE including gloves, overall/dust coat, and safety boots (Award 1 mark for correct PPE use or zero) | 1 | ||
| Handled tools and equipment according to workshop safety procedures (Award 1 mark for correct handling or zero) | 1 | ||
| Identified the compressor and explained its function in the AC charging system (Award up to 3 marks for correct identification and explanation) | 3 | ||
| Identified the condenser and explained its role in heat exchange (Award up to 3 marks for correct identification and explanation) | 3 | ||
| Identified the expansion valve and described its purpose in pressure regulation (Award up to 3 marks for correct identification and explanation) | 3 | ||
| Identified the evaporator and explained its function in cooling (Award up to 3 marks for correct identification and explanation) | 3 | ||
| Identified the receiver drier and explained its role in moisture removal (Award up to 3 marks for correct identification and explanation) | 3 | ||
| Identified the charging ports and explained their use during refrigerant charging (Award up to 3 marks for correct identification and explanation) | 3 | ||
| Used the manifold gauge set to demonstrate connection points for charging (Award up to 3 marks for correct demonstration) | 3 | ||
| Used the leak detector to demonstrate checking for refrigerant leaks at components (Award up to 3 marks for correct use and explanation) | 3 | ||
| Used the thermometer to measure temperature at evaporator or condenser and explained significance (Award up to 2 marks for correct measurement and explanation) | 2 | ||
| Prepared a brief oral or written explanation of the charging system components and their functions (Award up to 3 marks for clarity and completeness) | 3 | ||
| Performed housekeeping by cleaning workstation and returning tools (Award 1 mark for proper housekeeping) | 1 | ||
| Prepared a brief report listing identified components and their functions (Award up to 3 marks for report content and accuracy) | 3 | ||
| Sub-Total | 35 | ||
| PRODUCT CHECKLIST | |||
| Correct identification of all six key AC charging system components: compressor, condenser, expansion valve, evaporator, receiver drier, charging ports (Award 5 marks for all correct or proportionally less) | 5 | ||
| Clear and accurate explanation of each component’s function (Award 5 marks for clear and correct explanations) | 5 | ||
| Correct demonstration of manifold gauge connection points (Award 3 marks for correct demonstration) | 3 | ||
| Effective use of leak detector and thermometer with correct interpretation (Award 3 marks for effective use and interpretation) | 3 | ||
| Sub-Total | 16 | ||
| GRAND TOTAL | 51 | ||
Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Vacuum Pump | Refrigerant Charging Cylinder (R134a) |
| Manifold Gauge Set | Safety Gloves |
| Digital Thermometer | Safety Goggles |
| Leak Detector | Dust Coat/Overall |
| Insulated Screwdriver Set | Safety Boots |
| Adjustable Spanner | Clean Rags |
| Service Manual |
| S/N | Item | Quantity |
|---|---|---|
| 1 | Automobile Air Conditioning Unit (functional) | 1 Pc per Candidate |
| 2 | Vacuum Pump (capable of 500 microns) | 1 Set per Candidate |
| 3 | Manifold Gauge Set with hoses compatible with R134a | 1 Set per Candidate |
| 4 | Refrigerant Charging Cylinder (R134a) | 1 Cylinder per 5 Candidates |
| 5 | Digital Thermometer with probe | 1 Pc per Candidate |
| 6 | Leak Detector (electronic or soap foam) | 1 Pc per Candidate |
| 7 | Safety Gloves | 1 Pair per Candidate |
| 8 | Safety Goggles | 1 Pc per Candidate |
| 9 | Dust Coat/Overall | 1 Pc per Candidate |
| 10 | Safety Boots | 1 Pair per Candidate |
| 11 | Insulated Screwdriver Set | 1 Set per Candidate |
| 12 | Adjustable Spanner | 1 Pc per Candidate |
| 13 | Service Manual for the specific AC unit | 1 Pc per Station |
| 14 | Clean Rags | Enough per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Prepare and Connect Equipment | |||
| Wore appropriate PPE including gloves, goggles, dust coat, and safety boots (Award 1 mark for correct PPE use or zero) | 1 | ||
| Inspected AC system visually for leaks or damage before evacuation (Award 1 mark for thorough inspection or zero) | 1 | ||
| Connected manifold gauge set correctly to the service ports of the AC system (Award 1 mark for correct connection or zero) | 1 | ||
| Connected vacuum pump to the manifold gauge set correctly (Award 1 mark for proper connection or zero) | 1 | ||
| Sub-Total | 4 | ||
| TASK 2: Evacuate the AC System | |||
| Started vacuum pump and monitored gauge for pressure drop (Award 1 mark for correct operation or zero) | 1 | ||
| Achieved vacuum level of 500 microns or better within 15 minutes (Award 2 marks for achieving required vacuum level or zero) | 2 | ||
| Closed valves and observed gauge to ensure vacuum holds (no rise in pressure) for at least 5 minutes (Award 1 mark for proper vacuum hold check or zero) | 1 | ||
| Disconnected vacuum pump safely without introducing air into the system (Award 1 mark for safe disconnection or zero) | 1 | ||
| Sub-Total | 5 | ||
| TASK 3: System Leak Testing and Final Checks | |||
| Performed leak test using electronic leak detector or soap foam on all joints and connections (Award 2 marks for thorough leak testing or zero) | 2 | ||
| Cleaned the work area and equipment after completing evacuation (Award 1 mark for proper housekeeping or zero) | 1 | ||
| Prepared and submitted a service report including evacuation procedure and vacuum readings (Award 2 marks for complete and accurate report or zero) | 2 | ||
| Sub-Total | 5 | ||
| PRODUCT CHECKLIST | |||
| Vacuum level achieved is 500 microns or better as per specification (Award 3 marks for meeting or exceeding vacuum standard or zero) | 3 | ||
| No leaks detected after evacuation and leak test (Award 3 marks for no leaks or zero) | 3 | ||
| All connections are secure and system ready for charging (Award 2 marks for proper connection and readiness or zero) | 2 | ||
| Sub-Total | 8 | ||
| GRAND TOTAL | 22 | ||
At the start of this chapter we promised you would be able to:
Tick each one you can genuinely do.
So, are you there yet?
You're competent when you can confidently do 50% or more of what this chapter promised.
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