engine NISSAN 350Z 2007 Z33 Automatic Air Conditioner Workshop Manual

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

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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-12
PRECAUTIONS
Revision: 2006 November2007 350Z
Precautions for Servicing CompressorNJS00007

Plug all openings to prevent moisture and foreign matter from entering.

When the compressor is removed, store it in the same way at it is when mounted on the car.

When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compres-
sor” exactly. Refer to AT C - 2 1 , "
Maintenance of Lubricant Quantity in Compressor" .

Keep friction surfaces between clutch and pulley clean. If the surface is contaminated with lubri-
cant, wipe it off by using a clean waste cloth moistened with thinner.

After compressor service operation, turn the compressor shaft by hand more than five turns in
both directions. This will equally distribute lubricant inside the compressor. After the compressor
is installed, let the engine idle and operate the compressor for one hour.

After replacing the compressor magnet clutch, apply voltage to the new one and check for normal
operation.
Precautions for Service EquipmentNJS00008
RECOVERY/RECYCLING EQUIPMENT
Be certain to follow the manufacturer’s instructions for machine operation and machine maintenance. Never
introduce any refrigerant other than that specified into the machine.
ELECTRICAL LEAK DETECTOR
Be certain to follow the manufacturer’s instructions for tester operation and tester maintenance.
VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible
with the specified lubricant for HFC-134a (R-134a) A/C systems.
The vent side of the vacuum pump is exposed to atmospheric pres-
sure. So the vacuum pump lubricant may migrate out of the pump
into the service hose. This is possible when the pump is switched off
after evacuation (vacuuming) and hose is connected to it.
To prevent this migration, use a manual valve placed near the hose-
to-pump connection, as follows.

Usually vacuum pumps have a manual isolator valve as part of
the pump. Close this valve to isolate the service hose from the
pump.

For pumps without an isolator, use a hose equipped with a man-
ual shut-off valve near the pump end. Close the valve to isolate
the hose from the pump.

If the hose has an automatic shut-off valve, disconnect the hose
from the pump. As long as the hose is connected, the valve is
open and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close
under no vacuum condition. Such valves may restrict the pump’s
ability to pull a deep vacuum and are not recommended.
MANIFOLD GAUGE SET
Be certain that the gauge face indicates HFC-134a or R-134a. Be
sure the gauge set has 1/2″-16 ACME threaded connections for ser-
vice hoses. Confirm the set has been used only with refrigerant
HFC-134a (R-134a) and specified lubricants.
RHA270DA
SHA533D

ATC-14
PRECAUTIONS
Revision: 2006 November2007 350Z
Precautions for Leak Detection DyeNJS00009

The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet
(UV) lamp is required to illuminate the dye when inspecting for leaks.

Always wear fluorescence enhancing UV safety goggles to protect your eyes and enhance the visibility of
the fluorescent dye.

The fluorescent dye leak detector is not a replacement for an electrical leak detector (SST: J-41995). The
fluorescent dye leak detector should be used in conjunction with an electrical leak detector (SST: J-41995)
to pin-point refrigerant leaks.

For the purpose of safety and customer’s satisfaction, read and follow all manufacture’s operating instruc-
tions and precautions prior to performing the work.

A compressor shaft seal should not necessarily be repaired because of dye seepage. The compressor
shaft seal should only be repaired after confirming the leak with an electrical leak detector (SST: J-41995).

Always remove any remaining dye from the leak area after repairs are completed to avoid a misdiagnosis
during a future service.

Never allow dye to come into contact with painted body panels or interior components. If dye is spilled,
clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period
of time cannot be removed.

Never spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).

Never use more than one refrigerant dye bottle (1/4 ounce /7.4 cc) per A/C system.

Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Never use
HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system or CFC-12 (R-12) leak detection
dye in HFC-134a (R-134a) A/C system, or A/C system damage may result.

The fluorescent properties of the dye will remain for three years or a little over unless a compressor mal-
function occurs.
IDENTIFICATION
NOTE:
Vehicles with factory installed fluorescent dye have a green label.
Vehicles without factory installed fluorescent dye have a blue label.
IDENTIFICATION LABEL FOR VEHICLE
Vehicles with factory installed fluorescent dye have the identification label on the front side of hood.

LUBRICANT
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LUBRICANTPFP:KLG00
Maintenance of Lubricant Quantity in CompressorNJS0000I
The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compres-
sor when replacing any component or after a large refrigerant leakage occurred. It is important to maintain the
specified amount.
If lubricant quantity is not maintained properly, the following malfunctions may result:

Lack of lubricant: May lead to a seized compressor.

Excessive lubricant: Inadequate cooling (thermal exchange interference)
LUBRICANT
LUBRICANT RETURN OPERATION
Adjust the lubricant quantity according to the test group shown below.
1. CHECK LUBRICANT RETURN OPERATION
Can lubricant return operation be performed?

A/C system works properly.

There is no evidence of a large amount of lubricant leakage.
CAUTION:
If excessive lubricant leakage is noted, never perform the lubricant return operation.
OK or NG
OK >> GO TO 2.
NG >> GO TO 3.
2. PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS
1. Start the engine, and set to the following conditions:
–Engine speed: Idling to 1,200 rpm
–A/C switch: ON
–Blower speed: Max. position
–Temp. control: Optional [Set so that intake air temperature is 25 to 30°C (77 to 86°F).]
–Intake position: Recirculation (REC)
2. Perform lubricant return operation for about 10 minutes.
3. Stop the engine.
>> GO TO 3.
3. CHECK REPLACEMENT PART
Should the compressor be replaced?
YES >> GO TO AT C - 2 3 , "LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACE-
MENT" .
NO >> GO TO AT C - 2 2 , "
LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACE-
MENT EXCEPT COMPRESSOR" . Name : Nissan A/C System Oil Type S

ATC-26
AIR CONDITIONER CONTROL
Revision: 2006 November2007 350Z
Stop Signal:
At the end of each transmission, a stop operation, in-operation, or internal malfunction message is delivered to
the unified meter and A/C amp. This completes one data transmission and control cycle.
AIR MIX DOOR CONTROL (AUTOMATIC TEMPERATURE CONTROL)
The air mix door is automatically controlled so that in-vehicle temperature is maintained at a predetermined
value by the temperature setting, ambient temperature, in-vehicle temperature and amount of sunload.
FAN SPEED CONTROL
Blower speed is automatically controlled by the temperature setting, ambient temperature, in-vehicle tempera-
ture, intake temperature, amount of sunload and air mix door position.
With FAN control dial set to AUTO, the blower motor starts to gradually increase air flow volume.
When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from flow-
ing.
INTAKE DOOR CONTROL
The intake doors are automatically controlled by the temperature setting, ambient temperature, in-vehicle tem-
perature, intake temperature, amount of sunload and ON/OFF operation of the compressor.
MODE DOOR CONTROL
The mode door is automatically controlled by the temperature setting, ambient temperature, in-vehicle temper-
ature, intake temperature and amount of sunload.
RJIA2100E

TROUBLE DIAGNOSIS
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TROUBLE DIAGNOSISPFP:00004
CONSULT-III Function (BCM)NJS0000Q
CONSULT-III can display each diagnosis item using the diagnosis test modes shown following.
DATA MONITOR
Display Item List
System part Check item, diagnosis mode Description
BCM Data monitor Displays BCM input data in real time.
Monitor Item Condition Value/Status
IGNITION SW Ignition switch OFF → ON OFF → ON
HEATER FAN SW Ignition switch ONBlower fan motor switch ON ON
Blower fan motor switch OFF OFF
AIR COND SIG Ignition switch ONCompressor ON ON
Compressor ON OFF
AC PRESS SEN

Engine is running

Warm-up condition

Both A/C switch and blower fan motor switch: ON (Compressor
operates)1.0 - 4.0 V

TROUBLE DIAGNOSIS
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Component Parts and Harness Connector LocationNJS0000S
ENGINE COMPARTMENT
PJIA0175E

TROUBLE DIAGNOSIS
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Self-diagnosis FunctionNJS0000W
DESCRIPTION
The self-diagnosis system diagnoses sensors, door motors, blower motor, etc. by system line.
Self-diagnosis is STEP-1 to 7. There are two ways of changing method during self-diagnosis.

Switching to self-diagnosis STEP-1 to 4.
Shifting from normal control to the self-diagnosis system is accomplished by starting the engine (turning
the ignition switch from OFF to ON) and pressing A/C switch for at least 5 seconds. The A/C switch must
be pressed within 10 seconds after starting the engine (ignition switch is turned ON). This system will be
canceled by either pressing intake switch or turning the ignition switch OFF. Shifting to the next step is
accomplished by means of turning fan control dial, as required.

Switching to self-diagnosis STEP-5 to 7 (Auxiliary mechanism).
Shifting from normal control to the self-diagnosis system is accomplished by starting the engine (turning
the ignition switch from OFF to ON) and pressing intake switch for at least 5 seconds. The intake switch
must be pressed within 10 seconds after starting the engine (ignition switch is turned ON). This system
will be canceled by either pressing A/C switch or turning the ignition switch OFF. Shifting to the next step
is accomplished by means of turning fan control dial, as required.
SJIA1139E

ATC-46
TROUBLE DIAGNOSIS
Revision: 2006 November2007 350Z
FUNCTION CONFIRMATION PROCEDURE
1. SET IN SELF-DIAGNOSIS MODE (STEP-1 TO 4)
1. Set the fan control dial to OFF position.
2. Turn ignition switch ON.
3. Set in self-diagnosis mode as follows. Within 10 seconds after starting engine (ignition switch is turned
ON.), press A/C switch for at least 5 seconds.
NOTE:
If battery voltage drops below 12 V during diagnosis STEP-3, door motor speed becomes slower and as a
result, the system may generate an error even when operation is normal. To avoid this, start engine before
performing this diagnosis.
>> GO TO 2.
2. STEP-1: LEDS ARE CHECKED
Check intake and A/C switch LEDs illumination.
OK >> GO TO 3.
NG >> Refer to AT C - 9 1 , "
Self-diagnosis" .
3. CHECK TO ADVANCE SELF-DIAGNOSIS STEP-2
1. Turn fan control dial to AUTO position.
NOTE:
When switched to STEP-2, LED of REC position blinks for
approximately 25 seconds.
2. Check A/C switch LED illumination.
Advance to self
-diagnosis STEP-2?
YES >> GO TO 4.
NO >> Replace A/C controller. (Fan control dial is malfunction-
ing.)
4. CHECK TO RETURN SELF-DIAGNOSIS STEP-1
Turn fan control dial to OFF position.
Return to self
-diagnosis STEP-1?
YES >> GO TO 5.
NO >> Replace A/C controller. (Fan control dial is malfunctioning.)
S J I A 1111 E
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