NISSAN 350Z 2007 Z33 Automatic Air Conditioner Workshop Manual

ATC-1
AUTOMATIC AIR CONDITIONER
J AIR CONDITIONER
CONTENTS
C
D
E
F
G
H
I
K
L
M
SECTION AT C
A
B
AT C
Revision: 2006 November2007 350Z
AUTOMATIC AIR CONDITIONER
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 4
Precautions for Battery Service ................................ 4
Precautions for Procedures without Cowl Top Cover ..... 4
Precautions for Working with HFC-134a (R-134a) ..... 5
CONTAMINATED REFRIGERANT ....................... 5
General Refrigerant Precautions .............................. 6
Precautions for Refrigerant Connection ................... 7
ABOUT ONE-TOUCH JOINT ................................ 7
FEATURES OF NEW TYPE REFRIGERANT
CONNECTION ...................................................... 9
O-RING AND REFRIGERANT CONNECTION ... 10
Precautions for Servicing Compressor ................... 12
Precautions for Service Equipment ........................ 12
RECOVERY/RECYCLING EQUIPMENT ............ 12
ELECTRICAL LEAK DETECTOR ....................... 12
VACUUM PUMP ................................................. 12
MANIFOLD GAUGE SET .................................... 12
SERVICE HOSES ............................................... 13
SERVICE COUPLERS ........................................ 13
REFRIGERANT WEIGHT SCALE ...................... 13
CHARGING CYLINDER ...................................... 13
Precautions for Leak Detection Dye ....................... 14
IDENTIFICATION ................................................ 14
IDENTIFICATION LABEL FOR VEHICLE ........... 14
PREPARATION ......................................................... 15
Special Service Tools ............................................. 15
HFC-134a (R-134a) Service Tools and Equipment ... 16
Commercial Service Tools ...................................... 18
REFRIGERATION SYSTEM ..................................... 19
Refrigerant Cycle ................................................... 19
REFRIGERANT FLOW ....................................... 19
FREEZE PROTECTION ..................................... 19
Refrigerant System Protection ............................... 19
REFRIGERANT PRESSURE SENSOR ............. 19
PRESSURE RELIEF VALVE ............................... 19
Component Layout ................................................. 20LUBRICANT .............................................................. 21
Maintenance of Lubricant Quantity in Compressor ... 21
LUBRICANT ........................................................ 21
LUBRICANT RETURN OPERATION .................. 21
LUBRICANT ADJUSTING PROCEDURE FOR
COMPONENTS REPLACEMENT EXCEPT
COMPRESSOR .................................................. 22
LUBRICANT ADJUSTING PROCEDURE FOR
COMPRESSOR REPLACEMENT ....................... 23
AIR CONDITIONER CONTROL ............................... 24
Description of Air Conditioner LAN Control System ... 24
System Construction .............................................. 24
OPERATION ........................................................ 25
TRANSMISSION DATA AND TRANSMISSION
ORDER ............................................................... 25
AIR MIX DOOR CONTROL (AUTOMATIC TEM-
PERATURE CONTROL) ..................................... 26
FAN SPEED CONTROL ...................................... 26
INTAKE DOOR CONTROL ................................. 26
MODE DOOR CONTROL ................................... 26
MAGNET CLUTCH CONTROL ........................... 27
SELF-DIAGNOSIS SYSTEM .............................. 27
Description of Control System ................................ 28
Control Operation ................................................... 29
MODE CONTROL DIAL ...................................... 29
TEMPERATURE CONTROL DIAL (POTENTIO
TEMPERATURE CONTROL) .............................. 29
FAN CONTROL DIAL .......................................... 29
REAR WINDOW DEFOGGER SWITCH ............. 29
INTAKE SWITCH ................................................. 29
A/C SWITCH ....................................................... 29
Discharge Air Flow ................................................. 30
System Description ................................................. 31
SWITCHES AND THEIR CONTROL FUNCTION ... 31
CAN Communication System Description .............. 32
TROUBLE DIAGNOSIS ............................................ 33
CONSULT-III Function (BCM) ................................ 33
DATA MONITOR ................................................. 33
How to Perform Trouble Diagnosis for Quick and
Accurate Repair ...................................................... 34

ATC-2Revision: 2006 November2007 350Z WORK FLOW ...................................................... 34
SYMPTOM TABLE .............................................. 34
Component Parts and Harness Connector Location ... 35
ENGINE COMPARTMENT .................................. 35
PASSENGER COMPARTMENT .......................... 36
Schematic ............................................................... 37
Wiring Diagram — A/C — ....................................... 38
Auto Amp. Terminals and Reference Value ............ 43
PIN CONNECTOR TERMINAL LAYOUT ............ 43
TERMINALS AND REFERENCE VALUE FOR
UNIFIED METER AND A/C AMP. ........................ 43
Self-diagnosis Function .......................................... 45
DESCRIPTION .................................................... 45
FUNCTION CONFIRMATION PROCEDURE ...... 46
AUXILIARY MECHANISM: TEMPERATURE
SETTING TRIMMER ........................................... 50
AUXILIARY MECHANISM: FOOT POSITION
SETTING TRIMMER ........................................... 51
AUXILIARY MECHANISM: INLET PORT MEM-
ORY FUNCTION ................................................. 51
Operational Check .................................................. 53
CHECKING BLOWER ......................................... 53
CHECKING DISCHARGE AIR ............................ 53
CHECKING INTAKE DOOR ................................ 53
CHECKING TEMPERATURE DECREASE ......... 53
CHECKING TEMPERATURE INCREASE .......... 53
CHECKING A/C SWITCH ................................... 53
Power Supply and Ground Circuit for Auto Amp. ... 54
INSPECTION FLOW ........................................... 54
COMPONENT DESCRIPTION ............................ 54
DIAGNOSIS PROCEDURE FOR A/C SYSTEM ... 55
LAN System Circuit ................................................ 56
DIAGNOSIS PROCEDURE FOR LAN CIRCUIT ... 56
Mode Door Motor Circuit ........................................ 60
INSPECTION FLOW ........................................... 60
SYSTEM DESCRIPTION .................................... 61
COMPONENT DESCRIPTION ............................ 62
DIAGNOSIS PROCEDURE FOR MODE DOOR
MOTOR ............................................................... 62
Air Mix Door Motor Circuit ...................................... 63
INSPECTION FLOW ........................................... 63
SYSTEM DESCRIPTION .................................... 64
COMPONENT DESCRIPTION ............................ 65
DIAGNOSIS PROCEDURE FOR AIR MIX DOOR ... 65
Air Mix Door Motor PBR Circuit .............................. 65
DIAGNOSIS PROCEDURE FOR AIR MIX DOOR
MOTOR PBR ....................................................... 65
Intake Door Motor Circuit ........................................ 66
INSPECTION FLOW ........................................... 66
SYSTEM DESCRIPTION .................................... 67
COMPONENT DESCRIPTION ............................ 68
DIAGNOSIS PROCEDURE FOR INTAKE DOOR
MOTOR ............................................................... 68
Blower Motor Circuit ............................................... 69
INSPECTION FLOW ........................................... 69
SYSTEM DESCRIPTION .................................... 70
COMPONENT DESCRIPTION ............................ 71
DIAGNOSIS PROCEDURE FOR BLOWER
MOTOR ............................................................... 71COMPONENT INSPECTION ............................... 73
Magnet Clutch Circuit .............................................. 74
INSPECTION FLOW ............................................ 74
SYSTEM DESCRIPTION ..................................... 75
DIAGNOSIS PROCEDURE FOR MAGNET
CLUTCH .............................................................. 75
COMPONENT INSPECTION ............................... 80
Insufficient Cooling .................................................. 81
INSPECTION FLOW ............................................ 81
PERFORMANCE TEST DIAGNOSIS .................. 83
PERFORMANCE CHART .................................... 85
TROUBLE DIAGNOSIS FOR UNUSUAL PRES-
SURE ................................................................... 86
Insufficient Heating ................................................. 89
INSPECTION FLOW ............................................ 89
Noise ....................................................................... 90
INSPECTION FLOW ............................................ 90
Self-diagnosis ......................................................... 91
INSPECTION FLOW ............................................ 91
Ambient Sensor Circuit ........................................... 92
COMPONENT DESCRIPTION ............................ 92
AMBIENT TEMPERATURE INPUT PROCESS ... 92
DIAGNOSIS PROCEDURE FOR AMBIENT
SENSOR .............................................................. 92
COMPONENT INSPECTION ............................... 94
In-vehicle Sensor Circuit ......................................... 94
COMPONENT DESCRIPTION ............................ 94
DIAGNOSIS PROCEDURE FOR IN-VEHICLE
SENSOR .............................................................. 95
COMPONENT INSPECTION ............................... 96
Sunload Sensor Circuit ........................................... 97
COMPONENT DESCRIPTION ............................ 97
SUNLOAD INPUT PROCESS ............................. 97
DIAGNOSIS PROCEDURE FOR SUNLOAD
SENSOR .............................................................. 97
COMPONENT INSPECTION ............................... 99
Intake Sensor Circuit .............................................100
COMPONENT DESCRIPTION ..........................100
DIAGNOSIS PROCEDURE FOR INTAKE SEN-
SOR ...................................................................100
COMPONENT INSPECTION .............................101
A/C CONTROLLER .................................................102
Removal and Installation .......................................102
REMOVAL ..........................................................102
INSTALLATION ..................................................102
Disassembly and Assembly ..................................102
AUTO AMP ..............................................................103
Removal and Installation of Unified Meter and A/C
Amp. ......................................................................103
REMOVAL ..........................................................103
INSTALLATION ..................................................103
AMBIENT SENSOR ................................................104
Removal and Installation .......................................104
REMOVAL ..........................................................104
INSTALLATION ..................................................104
IN-VEHICLE SENSOR ............................................105
Removal and Installation .......................................105
REMOVAL ..........................................................105
INSTALLATION ..................................................105

ATC-3
C
D
E
F
G
H
I
K
L
MA
B
AT C
Revision: 2006 November2007 350Z SUNLOAD SENSOR .............................................. 106
Removal and Installation ...................................... 106
REMOVAL ......................................................... 106
INSTALLATION ................................................. 106
INTAKE SENSOR ................................................... 107
Removal and Installation ...................................... 107
REMOVAL ......................................................... 107
INSTALLATION ................................................. 107
BLOWER UNIT ....................................................... 108
Removal and Installation ...................................... 108
REMOVAL ......................................................... 108
INSTALLATION ................................................. 108
Disassembly and Assembly ................................. 109
BLOWER MOTOR ...................................................110
Removal and Installation ....................................... 110
REMOVAL .......................................................... 110
INSTALLATION .................................................. 110
INTAKE DOOR MOTOR .......................................... 111
Removal and Installation ...................................... . 111
REMOVAL ......................................................... . 111
INSTALLATION ................................................. . 111
HEATER & COOLING UNIT ASSEMBLY ...............112
Removal and Installation ....................................... 112
REMOVAL .......................................................... 112
INSTALLATION .................................................. 113
Disassembly and Assembly .................................. 114
MODE DOOR MOTOR ............................................116
Removal and Installation ....................................... 116
REMOVAL .......................................................... 116
INSTALLATION .................................................. 116
AIR MIX DOOR MOTOR ..........................................117
Removal and Installation ....................................... 117
REMOVAL .......................................................... 117
INSTALLATION .................................................. 117
HEATER CORE .......................................................118
Removal and Installation ....................................... 118
REMOVAL .......................................................... 118
INSTALLATION .................................................. 118
DUCTS AND GRILLES ...........................................119
Removal and Installation ....................................... 119
COMPONENT LAYOUT ..................................... 119
REMOVAL .......................................................... 119
INSTALLATION ................................................. 122
REFRIGERANT LINES ........................................... 123
HFC-134a (R-134a) Service Procedure ............... 123
SETTING OF SERVICE TOOLS AND EQUIP-
MENT ................................................................ 123
Components ......................................................... 125
Removal and Installation of Compressor ............. 125REMOVAL .........................................................125
INSTALLATION .................................................126
Check Disc to Pulley Clearance ...........................126
Removal and Installation of Low-pressure Flexible
Hose and Pipe 2 ...................................................127
REMOVAL .........................................................127
INSTALLATION .................................................128
Removal and Installation of High-pressure Flexible
Hose .....................................................................128
REMOVAL .........................................................128
INSTALLATION .................................................129
Removal and Installation of High-pressure Pipe 1
(Engine Compartment) .........................................130
REMOVAL .........................................................130
INSTALLATION .................................................130
Removal and Installation of Low-pressure Pipe 1
and High-pressure Pipe 2 .....................................131
REMOVAL .........................................................131
INSTALLATION .................................................132
Removal and Installation of Liquid Tank ...............132
REMOVAL .........................................................132
INSTALLATION .................................................133
Removal and Installation of Condenser ................133
REMOVAL .........................................................133
INSTALLATION .................................................134
Removal and Installation of Refrigerant Pressure
Sensor ..................................................................135
REMOVAL .........................................................135
INSTALLATION .................................................135
Removal and Installation of Evaporator ................135
REMOVAL .........................................................135
INSTALLATION .................................................135
Removal and Installation of Expansion Valve .......137
REMOVAL .........................................................137
INSTALLATION .................................................137
Checking for Refrigerant Leaks ............................138
Checking System for Leaks Using the Fluorescent
Leak Detector .......................................................138
Dye Injection .........................................................138
Electrical Leak Detector ........................................139
PRECAUTIONS FOR HANDLING LEAK
DETECTOR .......................................................139
CHECKING PROCEDURE ...............................140
SERVICE DATA AND SPECIFICATIONS (SDS) ....142
Compressor ..........................................................142
Lubricant ...............................................................142
Refrigerant ............................................................142
Engine Idling Speed .............................................142
Belt Tension ..........................................................142

ATC-4
PRECAUTIONS
Revision: 2006 November2007 350Z
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
NJS000D2
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING:

To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.

Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.

Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for Battery ServiceNJS000D3
Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interfer-
ence between the window edge and the vehicle when the door is opened/closed. During normal operation, the
window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic
window function will not work with the battery disconnected.
Precautions for Procedures without Cowl Top CoverNJS000CP
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
PIIB3706J

PRECAUTIONS
ATC-5
C
D
E
F
G
H
I
K
L
MA
B
AT C
Revision: 2006 November2007 350Z
Precautions for Working with HFC-134a (R-134a)NJS00003
CAUTION:

CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. If the refrigerants
are mixed and compressor malfunction is likely to occur, refer to “CONTAMINATED REFRIGER-
ANT” below. To determine the purity of HFC-134a (R-134a) in the vehicle and recovery tank, use
Refrigerant Recovery/Recycling Recharging equipment and Refrigerant Identifier.

Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-
nents. If lubricant other than that specified is used, compressor malfunction is likely to occur.

The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-
lowing handling precautions must be observed:
–When removing refrigerant components from a vehicle, immediately cap (seal) the component to
minimize the entry of moisture from the atmosphere.
–When installing refrigerant components to a vehicle, never remove the caps (unseal) until just
before connecting the components. Connect all refrigerant loop components as quickly as possi-
ble to minimize the entry of moisture into system.
–Only use the specified lubricant from a sealed container. Immediately reseal containers of lubri-
cant. Without proper sealing, lubricant will become moisture saturated and should not be used.
–Never allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrene foam parts.
Damage may result.
CONTAMINATED REFRIGERANT
If a refrigerant other than pure HFC-134a (R-134a) is identified in a vehicle, take appropriate steps
shown below:

Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant
into the atmosphere.

Explain that recovery of the contaminated refrigerant could damage service equipment and refrigerant
supply.

Suggest the customer return the vehicle to the location of previous service where the contamination may
have occurred.

In case of repairing, recover the refrigerant using only dedicated equipment and containers. Never
recover contaminated refrigerant into the existing service equipment. If the facility does not have
dedicated recovery equipment, contact a local refrigerant product retailer for available service. This refrig-
erant must be disposed of in accordance with all federal and local regulations. In addition, replacement of
all refrigerant system components on the vehicle is recommended.

If the vehicle is within the warranty period, the air conditioner warranty is void. Please contact Nissan Cus-
tomer Affairs for further assistance.

ATC-6
PRECAUTIONS
Revision: 2006 November2007 350Z
General Refrigerant PrecautionsNJS00004
WARNING:

Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Remove HFC-134a (R-134a) from the A/C system, using certified service equipment meet-
ing requirements of SAE J-2210 [HFC-134a (R-134a) recycling equipment], or J-2209 [HFC-134a (R-
134a) recovery equipment]. If accidental system discharge occurs, ventilate work area before
resuming service. Additional health and safety information may be obtained from refrigerant and
lubricant manufacturers.

Never release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged.

Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioning system.

Never store or heat refrigerant containers above 52°C (126°F).

Never heat a refrigerant container with an open flame; if container warming is required, place the
bottom of the container in a warm pail of water.

Never intentionally drop, puncture, or incinerate refrigerant containers.

Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.

Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation.

Never pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air condition-
ing systems with compressed air during repair. Some mixtures of air and HFC-134a (R-134a) have
been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury
or property damage. Additional health and safety information may be obtained from refrigerant
manufacturers.

PRECAUTIONS
ATC-7
C
D
E
F
G
H
I
K
L
MA
B
AT C
Revision: 2006 November2007 350Z
Precautions for Refrigerant ConnectionNJS00006
A new type refrigerant connection has been introduced to all refrigerant lines except the following location.

Expansion valve to evaporator

Refrigerant pressure sensor to liquid tank
ABOUT ONE-TOUCH JOINT
Description

One-touch joints are pipe joints which do not require tools during piping connection.

Unlike conventional connection methods using union nuts and flanges, controlling tightening torque at
connection point is not necessary.

When removing a pipe joint, use a disconnector.
COMPONENT PARTS
FUNCTIONS OF COMPONENT PARTS
NOTE:

Garter spring (2) cannot be removed from cage (A) of male-side piping.

Indicator ring (3) remains near piping connection point, however, this is not a malfunction. (This is to
check piping connection during factory assembly.)
1 Pipe (Male-side)
Retains O-rings (4).

Retains garter spring (2) in cage (A).
2 Garter spring Anchors female-side piping (5).
3 Indicator ringWhen connection is made properly, this is ejected from male-side piping (1). (This part is no longer
necessary after connection.)
4 O-ring Seals connection point. (Not reusable)
5 Pipe (Female-side)

Seals connection by compressing O-rings (4).

Anchors piping connection using flare (B) and garter spring (2).
RJIA4383J

ATC-8
PRECAUTIONS
Revision: 2006 November2007 350Z
REMOVAL
1. Clean piping connection point, and set a disconnector.
2. Slide disconnector in axial direction of piping, and stretch garter spring with tapered point of disconnector.
3. Slide disconnector farther so that inside diameter of garter spring becomes larger than outside diameter of
female-side piping flare. Then male-side piping can be disconnected.
INSTALLATION
1. Clean piping connection points, and insert male-side piping into female-side piping.
2. Push inserted male-side piping harder so that female-side piping flare stretches garter spring.
3. If inside diameter of garter spring becomes larger than outside diameter of female-side piping flare, garter
spring seats on flare. Then, it fits in between male-side piping cage and female-side piping flare to anchor
piping connection point.
NOTE:
When garter spring seats on flare, and fits in between male-side piping cage and female-side piping flare,
it clicks.
CAUTION:

Female-side piping connection is thin and easy to deform. Slowly insert the male-side piping
straight in axial direction.

Insert piping securely until a click is heard.
SJIA0106E
SJIA0107E

PRECAUTIONS
ATC-9
C
D
E
F
G
H
I
K
L
MA
B
AT C
Revision: 2006 November2007 350Z

After piping connection is completed, pull male-side piping by hand to make sure that connec-
tion does not come loose.
NOTE:
One-touch joint connection is used in points below.

Low-pressure pipe 2 to low-pressure pipe 1 (O-ring size: 16)

Low-pressure pipe 2 to low-pressure flexible hose (O-ring size: 16)

High-pressure flexible hose to condenser (O-ring size: 12)

High-pressure pipe 1 to high-pressure pipe 2 (O-ring size: 8)

High-pressure pipe 1 to condenser (O-ring size: 8)
FEATURES OF NEW TYPE REFRIGERANT CONNECTION

The O-ring has been relocated. It has also been provided with a groove for proper installation. This elimi-
nates the possibility of the O-ring being caught in, or damaged by, the mating part. The sealing direction of
the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing
characteristics.

The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facil-
itating piping connections.
SHA815E

ATC-10
PRECAUTIONS
Revision: 2006 November2007 350Z
O-RING AND REFRIGERANT CONNECTION
CAUTION:
The new and former refrigerant connections use different O-ring configurations. Never confuse O-
rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant may leak at the con-
nection.
O-Ring Part Numbers and Specifications
PJIA0173E
Connection type Piping connection point Part number QTY O-ring size
NewLow-pressure pipe 2 to low-pressure pipe 1 (One-touch
joint)92473 N8221 2 16
Low-pressure pipe 2 to low-pressure flexible hose (One-
touch joint)92473 N8221 2 16
High-pressure pipe 1 to high-pressure pipe 2 (One-touch
joint)92471 N8221 2 8
Condenser to high-pressure flexible hose (One-touch joint) 92472 N8221 2 12
Condenser to high-pressure pipe 1 (One-touch joint) 92471 N8221 2 8
Low-pressure pipe 1 to expansion valve 92473 N8210 1 16
High-pressure pipe 2 to expansion valve 92471 N8210 1 8
Compressor to low-pressure flexible hose 92474 N8210 1 19
Compressor to high-pressure flexible hose 92472 N8210 1 12
Liquid tank to condenser pipeInlet
92471 N82101
8
Outlet 1