2005 LEXUS ES300 Repair Manual

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))

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)

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.

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
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
COMPONENTS

550DI-02
I31538
I31539
I31540
- HEATER & AIR CONDITIONERCOOLER CONDENSER ASSY
55-45
2660 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
HINT:
COMPONENTS: See page 55-44
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. REMOVE COOLER REFRIGERANT DISCHARGE
HOSE NO.1
(a) Remove the bolt and disconnect the cooler refrigerant
discharge hose No. 1 from the cooler condenser assy.
(b) Remove the O-ring from the cooler refrigerant discharge
hose No. 1.
NOTICE:
Seat the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matter from entering.
3. DISCONNECT COOLER REFRIGERANT LIQUID PIPE
A
(a) Remove the bolt and disconnect the cooler refrigerant liq-
uid pipe A from the cooler condenser assy.
(b) Remove the O-ring from the cooler refrigerant liquid pipe
A.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matter from entering.
4. REMOVE AIR CLEANER INLET ASSY (See page 16-21)
5. REMOVE RADIATOR SUPPORT UPPER (See page 16-21)
6. REMOVE COOLER CONDENSER ASSY
(a) Remove the 2 nuts and cooler condenser assy.

I30086
10 mm
(0.39 in.)
Hexagon
Wrench
Modulator
E50132
E57114
E50386
E50132
I30086
10 mm
(0.39 in.)
Hexagon
Wrench
Modulator
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- HEATER & AIR CONDITIONERCOOLER CONDENSER ASSY
2661 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
7. REMOVE COOLER DRYER
(a) Using hexagon wrench 10 mm (0.39 in.), remove the cap
and filter from the modulator.
(b) Remove the 2 O-rings from the cap.
(c) Using a needle nose pliers, remove the cooler dryer.
8. INSTALL COOLER DRYER
(a) Using a needle nose pliers, install the cooler dryer.
(b) Install 2 new O-rings to the cap.
(c) Sufficiently apply compressor oil to the fit surfaces of the
O-ring and the cap.
Compressor oil: ND-OIL 8 or equivalent
(d) Using hexagon wrench 10 mm (0.39 in.), install the cap
to the condenser assy.
Torque: 12 NVm (125 kgfVcm, 9 ftVlbf)

I31541
I31539
I31538
- HEATER & AIR CONDITIONERCOOLER CONDENSER ASSY
55-47
2662 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
9. INSTALL COOLER CONDENSER ASSY
(a) Install the cooler condenser assy with the 2 nuts.
Torque: 9.8 NVm (100 kgfVcm, 85 in.Vlbf)
10. INSTALL RADIATOR SUPPORT UPPER (See page 16-21)
11. INSTALL COOLER REFRIGERANT LIQUID PIPE A
(a) Remove the attached vinyl tape from the tube and con-
necting part of the cooler condenser assy.
(b) Sufficiently apply compressor oil to the new O-ring and
tube joint.
Compressor oil: ND-OIL 8 or equivalent
(c) Install a O-ring to the cooler refrigerant liquid pipe A.
(d) Connect the cooler refrigerant liquid pipe A to the cooler
condenser assy with the bolt.
Torque: 5.4 NVm (55 kgfVcm, 47 in.Vlbf)
12. INSTALL COOLER REFRIGERANT DISCHARGE
HOSE NO.1
(a) Remove the attached vinyl tape from the tube and con-
necting part of the cooler condenser assy.
(b) Sufficiently apply compressor oil to the new O-ring and
tube joint.
Compressor oil: ND-OIL 8 or equivalent
(c) Install a O-ring to the cooler refrigerant discharge hose
No. 1.
(d) Connect the cooler refrigerant discharge hose No. 1 to
the cooler condenser assy with the bolt.
Torque: 5.4 NVm (55 kgfVcm, 47 in.Vlbf)

55-48
- HEATER & AIR CONDITIONERCOOLER CONDENSER ASSY
2663 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
13. 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.)
14. WARM UP ENGINE
15. INSPECT LEAKAGE OF REFRIGERANT (See page 55-8)