2005 LEXUS ES300 Repair Manual

550DB-02
I03839
Push
SSTPull
Release
Lever
I06919
Screw
Driver Disconnect the
tube using hand
I31522
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55-17
2632 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
HINT:
COMPONENTS: See page 55-15
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 55-8)
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070,
07117-88080)
2. DISCONNECT COOLER REFRIGERANT SUCTION
HOSE NO.1
(a) Install SST to piping clamp.
SST 09870-00015
HINT:
Confirm the direction of the piping clamp claw and SST using
the illustration showing on the caution label.
(b) Push down SST and release the clamp lock.
NOTICE:
Be careful not to deform the tube, when pushing SST.
(c) Pull SST slightly and push the release lever, then remove
the piping clamp with SST.
(d) Disconnect the cooler refrigerant suction hose No. 1.
NOTICE:

Do not use tools like screwdriver to remove the tube.

Cap the open fittings immediately to keep moisture or
dirt out of the system.
3. DISCONNECT COOLER REFRIGERANT LIQUID PIPE A
SST 09870-00025
HINT:
Disconnect cooler refrigerant liquid pipe A in the same way as the cooler refrigerant suction hose No. 1.
4. DISCONNECT HEATER OUTLET WATER HOSE
(a) Using pliers, grip the claws of clip and slide the clip and
disconnect the heater outlet water hose.

I31636
I31637
I31497
55-18
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
2633 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
5. DISCONNECT HEATER INLET WATER HOSE
HINT:
Disconnect in the same way as the heater outlet water hose.
6. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See page 71-1 1)
HINT:
Refer to the instructions for removal of the instrument panel safety pad sub-assy.
7. REMOVE AIR DUCT REAR NO.1
(a) Remove the 2 screws, bolt and nut.
(b) Remove the air duct rear No. 1.
8. REMOVE AIR DUCT REAR NO.2
(a) Remove the 2 screws, bolt and nut.
(b) Remove the air duct rear No. 2.
9. REMOVE CONSOLE BOX DUCT NO.1
(a) Remove the clip and console box duct No. 1.
10. DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY
11. REMOVE WINDSHIELD WIPER RELAY ASSY
12. REMOVE HEADLAMP LEVELING ECU ASSY

I31766
I315812 Clamps
I31501
I31502
I317682 Clamps
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55-19
2634 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
13. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY
NO.1
(a) Remove the bolt and earth wire.
(b) Release the 2 clamps.
(c) Remove the bolt and screw.
(d) Remove the nut and instrument panel brace sub-assy
No. 1.
14. REMOVE INSTRUMENT FINISH PANEL RETAINER
LOWER
(a) Remove the 2 bolts and instrument finish retainer lower.
15. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY
NO.2
(a) Remove the 2 clamps, nut and passenger side junction
block.

I31767
I31504
I31499
I31500
I31505
55-20
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
2635 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Remove the 2 bolts and 2 earth wires.
(c) Remove the 2 nuts, bolt and instrument panel brace sub-
assy No. 2.
16. REMOVE HEATER TO FOOT DUCT NO.3
(a) Remove the clip and heater to foot duct No. 3.
17. REMOVE HEATER TO FOOT DUCT NO.1
(a) Remove the clip and heater to foot duct No. 1.
18. DISCONNECT STEERING COLUMN ASSY
(a) Remove the 3 nuts and driver side junction block.

I31577
I315062 Clamps
I3176910 Clamps
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55-21
2636 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Remove the 2 nuts and steering side connector block.
(c) Release the 2 clamps.
(d) Remove the 3 bolts, disconnect the steering column assy.
19. REMOVE INSTRUMENT PANEL REINFORCEMENT
(a) Disconnect the 10 clamps and the wire harness.

I31770
I31771
I31563Clamp 55-22
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
2637 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Remove the 3 nuts, disconnect the 3 earth wires.
(c) Remove the 3 caps, 7 bolts and instrument panel rein-
forcement.
20. REMOVE BLOWER ASSY
(a) Disconnect the connectors.
(b) Remove the screw, clamp and blower connector holder.

I317726 Clamps
I31509
I315104 Claws
I31511
I31512
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55-23
2638 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Disconnect the 6 clamps and the wire harness.
(d) Remove the 2 screws, 2 nuts and blower assy.
21. REMOVE DEFROSTER NOZZLE ASSY LOWER
(a) Release the 4 fitting claws, remove the defroster nozzle
assy lower.
22. REMOVE AIR CONDITIONING RADIATOR ASSY
(a) Remove the 2 nuts and air conditioning radiator assy.
23. REMOVE MODE DAMPER SERVO SUB-ASSY
(a) Remove the 3 screws and mode damper servo sub-assy.

I31514
I31638
I315132 Claws
I31515
I31516
55-24
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
2639 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
24. REMOVE AIRMIX DAMPER SERVO SUB-ASSY
(a) LH side:
Remove the 3 screws and air mix damper servo sub-
assy.
(b) RH side:
Remove the 3 screws and air mix damper servo sub-
assy.
25. REMOVE HEATER RADIATOR UNIT SUB-ASSY
(a) Release the 2 fitting claws, remove the piping clamp.
(b) Remove the heater radiator unit sub-assy.
NOTICE:
Prepare a support plate and waste to catch the leaked cool-
ant.
26. REMOVE AIR CONDITIONING TUBE ASSY
(a) Remove the packing.
(b) Using a hexagon wrench 4 mm (0.16 in.), remove the 2
hexagon bolts and air conditioning tube assy.
(c) Remove the 2 O-rings from the air conditioning tube assy.