Page 31 of 969
I31502
I31501
I315812 Clamps
I31766
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55-31
2646 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
39. INSTALL INSTRUMENT FINISH PANEL RETAINER
LOWER
(a) Install the instrument finish panel retainer lower with the
2 bolts.
40. INSTALL INSTRUMENT PANEL BRACE SUB-ASSY
NO.1
(a) Install the instrument panel brace sub-assy No. 1 with the
nut.
(b) Install the bolt and screw.
Torque: 9.8 NVm (100 kgfVcm, 87 in.Vlbf) (Screw)
(c) Install the 2 clamps.
(d) Install the earth wire with the bolt.
Torque: 8.4 NVm (85 kgfVcm, 73 in.Vlbf)
41. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See page 71-1 1)
Page 33 of 969
550DC-02
I31634NVm (kgfVcm, ftVlbf): Specified torque
1.5 (15, 12 in.Vlbf)
Blower Assy
1.5 (15, 12 in.Vlbf)
Recirculation Damper Servo Sub-assy
Air Refiner ElementCowl Wire No. 2 Heater To Foot Duct No. 1
Blower w/ fan Motor Sub-assy
Instrument Panel No. 3 Wire Blower Motor Control
- HEATER & AIR CONDITIONERBLOWER ASSY
55-33
2648 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BLOWER ASSY
COMPONENTS
Page 36 of 969
550DE-02
I31774
18 (184, 13)
Non-reusable part
NVm (kgfVcm, ftVlbf): Specified torque Magnet Clutch WasherSnap Ring Magnet Clutch Assy
Cooler Compressor Assy
Snap Ring
Cooler Compressor Bracket
55-36
- HEATER & AIR CONDITIONERCOOLER COMPRESSOR ASSY
2651 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
COOLER COMPRESSOR ASSY
COMPONENTS
Page 40 of 969
I31548
I30369
I30363
E58517
55-40
- HEATER & AIR CONDITIONERCOOLER COMPRESSOR ASSY
2655 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(f) Using a vise pliers, hold the magnet clutch hub and install
the bolt.
Torque: 18 NVm (184 kgfVcm, 13 ftVlbf)
11. INSPECT MAGNETIC CLUTCH CLEARANCE
(a) Set the dial indicator to the magnet clutch hub.
(b) Connect the battery positive lead to the terminal 3 of mag-
net clutch connector and the negative lead to the earth
wire. Turn on and off the magnet clutch and measure the
clearance.
Standard clearance:
0.35 - 0.60 mm (0.014 - 0.024 in.)
If the measured value is out of the standard range, remove the
magnet clutch hub and adjust it with magnet clutch washers.
NOTICE:
Adjustment shall be performed with 3 or less magnet
clutch washers.
(c) Remove the compressor and magnetic clutch from the
vise.
(d) Install the bolt and bracket.
12. INSTALL COOLER COMPRESSOR BRACKET
(a) Install the earth wire and cooler compressor bracket with
the screw.
Page 41 of 969
I31546
I31561
(A)
(B)
I31544
(E)
(C)(D)
- HEATER & AIR CONDITIONERCOOLER COMPRESSOR ASSY
55-41
2656 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
13. INSPECT COMPRESSOR OIL
(a) When replacing the compressor and magnetic clutch with new one, after gradually removing the refrig-
erant gas from the service valve, drain the following amount of oil from the new compressor and mag-
netic clutch before installation.
Standard:
(Oil capacity inside new compressor and magnetic clutch: 120 + 15 cc (4.1 + 0.51 fl.oz.) ) - (Re-
maining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be re-
moved when replacing)
NOTICE:
When checking the compressor oil level, observe the precautions on the cooler removal/instal-
lation.
Because compressor oil remains in the pipes of the vehicle, if a new compressor and magnetic
clutch is installed without removing some oil inside, the oil amount becomes too much, pre-
venting heat exchange in the refrigerant cycle and causing refrigerant failure.
If the remaining oil in the removed compressor and magnetic clutch is too small in volume,
check for oil leakage.
Be sure to use ND-OIL8 for compressor oil.
14. TEMPORARY TIGHTEN COMPRESSOR AND
MAGNETIC CLUTCH
(a) Temporarily the compressor and magnetic clutch with the
3 bolts.
15. FULLY TIGHTEN COMPRESSOR AND MAGNETIC
CLUTCH
(a) Tighten the compressor and magnetic clutch with the bolt
(A) and bolt (B).
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
(b) Install the cooler compressor bracket with the 2 bolts and
nut.
Torque:
25 NVm (250 kgfVcm, 18 ftVlbf) (Bolt (C))
25 NVm (250 kgfVcm, 18 ftVlbf) (Nut (D))
18 NVm (184 kgfVcm, 13 ftVlbf) (Bolt (E))
Page 42 of 969
I31562
(F)
I31542
I31543
55-42
- HEATER & AIR CONDITIONERCOOLER COMPRESSOR ASSY
2657 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Tighten the compressor and magnetic clutch with the bolt
(F).
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
(d) Connect the connector.
16. INSTALL COOLER REFRIGERANT SUCTION HOSE
NO.1
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to the new O-ring and
fit surface of the compressor and magnetic clutch.
Compressor oil: ND-OIL 8 or equivalent
(c) Install a O-ring to the cooler refrigerant suction hose
No. 1.
(d) Install the cooler refrigerant suction hose No. 1 to the
compressor and magnetic clutch with the nut.
Torque: 9.8 NVm (100 kgfVcm, 87 in.Vlbf)
17. INSTALL COOLER REFRIGERANT DISCHARGE
HOSE NO.1
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to the new O-ring and
fit surface of the compressor and magnetic clutch.
Compressor oil: ND-OIL 8 or equivalent
(c) Install a O-ring to the cooler refrigerant discharge hose
No. 1.
(d) Install the cooler refrigerant discharge hose No. 1 to the
compressor and magnetic clutch with the nut.
Torque: 9.8 NVm (100 kgfVcm, 87 in.Vlbf)
18. INSTALL GENERATOR ASSY (See page 19-21)
19. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 55-10)
20. CHARGE REFRIGERANT (See page 55-8)
SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050,
07117-88060, 07117-88070, 07117-88080)
Specified amount: 550 50 g (19.37 1.76 oz.)
21. WARM UP ENGINE
22. INSPECT LEAKAGE OF REFRIGERANT (See page 55-8)
Page 43 of 969
550DG-02
- HEATER & AIR CONDITIONERCOOLER CONDENSER ASSY
55-43
2658 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
COOLER CONDENSER ASSY
ON-VEHICLE INSPECTION
1. INSPECT COOLER CONDENSER ASSY
(a) If a fin of the cooler condenser assy is dirty, clean it with water and dry it with compressor air.
NOTICE:
Do not damage the fin of the condenser assy.
(b) If a fin of the condenser assy is bent, make it straight using a screwdriver or pliers.
2. INSPECT CONDENSER FOR LEAKAGE OF REFRIGERANT
(a) Using a halogen leak detector, check pipe joints for gas leakage.
(b) If gas leakage is detected in a joint, check the torque of the joint.
Page 44 of 969
550DH-02
I31635
Radiator Support Upper
O-ring
Cooler Condenser Assy
Cooler Dryer
Filter
Cap
9.8 (100, 85 in.Vlbf)
Non-reusable parts Compressor oil ND-OIL 8 or equivalent
9.8 (100, 85 in.Vlbf)
O-ring 5.4 (55, 47 in.Vlbf)
O-ring
12 (125, 9)
Air Cleaner Inlet No. 1
Air Cleaner Inlet Assy
NVm (kgfVcm, ftVlbf): Specified torque
Radiator Lower Air Deflector
Hood Lock Release Lever
Protector
55-44
- HEATER & AIR CONDITIONERCOOLER CONDENSER ASSY
2659 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
COMPONENTS
