2005 LEXUS ES300 Torque mount
[x] Cancel search: Torque mountPage 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 129 of 969
D26766
SST
D26389
Rear Clutch
Oil Seal
Ring Outer
D26388
D26454
FIPG
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40-57
81 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
113. INSTALL NEEDLE ROLLER BEARING
(a) Using SST and a press, install the needle roller bearing
to the transaxle rear cover.
SST 09950-60010 (09951-00230, 09952-06010)
Press fit depth: 20.55 - 21.25 mm (0.8091 - 0.8366 in.)
NOTICE:
Face the inscribed mark side of the bearing race up.
Repeat the press fit until the specified value is ob-
tained.
(b) Coat a needle roller bearing with ATF.
114. INSTALL REAR CLUTCH OIL SEAL RING OUTER
(a) Coat the 3 new rear clutch oil seal rings with ATF, install
them to the transaxle rear cover.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
115. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Install the 4 new O-ring to the 4 transaxle case No. 1
plugs.
(b) Install the 4 transaxle case No. 1 plugs to the transaxle
rear cover.
Torque: 7.4 NVm (75 kgfVcm, 65 in.Vlbf)
116. INSTALL TRANSAXLE REAR COVER SUB-ASSY
(a) Remove any packing material and be careful not to get oil
on the contacting surfaces of the transaxle rear cover or
the transaxle case.
(b) Apply FIPG to the cover.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equiva-
lent.
NOTICE:
Concerning about the amount of the FIPG application, the
amount should be controlled to from even sealing film on
entire flange surface and have slight protrusion of the FIPG
all around of the connecting area. The FIPG shall be ap-
plied continuously on the flange. (Reference value of the
section diameter: f1.2)
Page 207 of 969
4010Q-02
D31337
Bearing Bracket Hole Snap Ring
32 (326, 24)
12 (122, 9)
64 (653, 47)
46 (470, 34)
Front Drive Shaft Assy RH
Transmission Control
Cable Bracket No.2
41 (418, 30)
12 (122, 9)
37 (377, 27)
5.5 (56, 49 in.Vlbf)
9.8 (100, 87 in.Vlbf)
Wire Harness
Automatic
Transmission Case
Cover
Front Drive
ShaftLH Hole
Snap Ring
Front Drive Shaft
Assy LH
Starter Assy
O-ring
Transimission Oil
Filler Tube Sub-assy
ATF Level
Gauge Oil Cooler
Outlet Tube No.1 Oil Cooler Inlet
Tube No.1Oil Cooler Tube ClampTransmission Control
Cable Bracket No.1 Flywheel Housing
Under CoverTorque Converter ClutchEngine
Mounting
Bracket FR
X6
N´m (kgf´cm, ft´lbf): Specified torque
Non-reusable partWire Harness Clamp
12 (122, 9)
12 (122, 9)
34 (350, 25)
8.4 (86, 74 in.Vlbf)
64 (653, 47)
5.4 (55, 48 in.Vlbf)
7.8 (80, 69 in.Vlbf)
13 (130, 9)
Exhaust Pipe Support Bracket
37 (377, 27)
34 (350, 25)
x 5 40-8
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E)
2523 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
AUTOMATIC TRANSAXLE ASSY (U151E)
COMPONENTS
Page 212 of 969
C83051
D31341Dimension B
B
D30511D31482
AA
A
A
BA
CC
D30472
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E)
40-13
2528 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
19. INSTALL TORQUE CONVERTER CLUTCH ASSY
(a) Install the torque converter clutch to the automatic trans-
axle.
(b) Using vernier calipers, measure dimension ºAº between
the transaxle fitting part and the converter fitting part of
the drive plate.
(c) Using vernier calipers and a straight edge, measure di-
mension ºBº shown in the illustration and check that ºBº
is greater than ºAº measured in (b).
Standard: A + 1 mm or more
NOTICE:
Do not add the thickness of the straight edge.
20. INSTALL AUTOMATIC TRANSAXLE ASSY
(a) Install the automatic transaxle and 8 bolts to the engine.
Torque:
Bolt A: 64 NVm (653 kgfVcm, 47 ftVlbf)
Bolt B: 46 NVm (470 kgfVcm, 34 ftVlbf)
Bolt C: 37 NVm (377 kgfVcm, 27 ftVlbf)
(b) Apply a few drops of adhesive to each 2 threads on the
tip of the 6 torque converter clutch mounting bolts.
Adhesive: Part No. 08833-00070, THREE BOND 1324
or equivalent
(c) Install the 6 torque converter clutch mounting bolts.
Torque: 41 NVm (418 kgfVcm, 30 ftVlbf)
HINT:
First install green colored bolt, and then install the other 5 bolts.
Page 213 of 969
D31340
D25420
C88135
D31339
Breather Hose
C88278
40-14
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E)
2529 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Install the flywheel housing under cover with the 2 bolts.
Torque: 7.8 NVm (80 kgfVcm, 69 in.Vlbf)
21. INSTALL ENGINE MOUNTING BRACKET FR
(a) Install the engine mounting bracket FR with the 3 bolts to
the automatic transaxle.
Torque: 64 NVm (653 kgfVcm, 47 ftVlbf)
22. INSTALL TRANSMISSION OIL FILLER TUBE
SUB-ASSY
(a) Coat a new O-ring with ATF, and install it to the oil filler
tube.
(b) Install the oil filler tube with the bolt to the automatic trans-
axle.
Torque: 5.5 NVm (56 kgfVcm, 49 in.Vlbf)
(c) Install the ATF level gauge.
(d) Connect the breather hose to the wire harness bracket.
23. INSTALL TRANSMISSION CONTROL CABLE
BRACKET NO.1
(a) Install the control cable bracket No.1 with the 2 bolts.
Torque: 12 NVm (122 kgfVcm, 9 ftVlbf)
24. INSTALL OIL COOLER INLET TUBE NO.1
(a) Temporarily install the oil cooler outlet tube No.1.
(b) Temporarily install the oil cooler inlet tube No.1.
Page 216 of 969
40063-10
AT0953
SST
AT3306
Hold
TurnLock
Free
D25367
Sample showing minimum amount of
powders in ATF
Actual Size
- AUTOMATIC TRANSMISSION / TRANSTORQUE CONVERTER CLUTCH AND DRIVE PLATE
40-17
2532 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
TORQUE CONVERTER CLUTCH AND DRIVE PLATE
INSPECTION
1. INSPECT TORQUE CONVERTER CLUTCH ASSY
(a) Inspect the one-way clutch.
(1) Set SST into the inner race of the one-way clutch.
SST 09350-32014 (09351-32010)
(2) Install SST so that it fits in the notch of the converter
hub and outer race of the one-way clutch.
SST 09350-32014 (09351-32020)
(3) With the torque converter clutch setting up on its
side, check that the one-way clutch locks when it is
turned counterclockwise, and rotates clockwise
smoothly.
If necessary, clean the converter and retest the one- way
clutch.
Replace the converter if the one-way clutch still fails the test.
(b) Determine the condition of the torque converter clutch
assy.
(1) If the inspection result of the torque converter clutch
assy meets the following item, replace the torque
converter clutch.
Malfunction item:
Any metallic sound is heard from the torque convert-
er clutch during stall test or when the shift lever is in
neutral position.
One-way clutch is free or locked in both directions.
Fine powders exceeding the sample limit is identified
in ATF. (See the sample.)
HINT:
The sample shows the auto fluid of approx. 0.25 liters (0.26 US
qts, 0.22 Imp. qts) that is taken out from the removed torque
converter clutch
(c) Replace the ATF in the torque converter clutch.
(1) If the ATF is discolored and/or has a foul odor, com-
pletely stir the ATF in the torque converter clutch
and drain it with the face for installation facing up.
Page 276 of 969
320E5-02
F41863
Front Disc
Front Disc Brake
Bleeder Plug
Front Flexible Hose Union Bolt
Gasket
Front Disc Brake
Bleeder Plug Cap
Disc Brake
Cylinder Assy LH
Set Ring
Cylinder BootFront Disc
Brake Piston
Piston Seal
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Slide Bush
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Bush Dust Boot
Front Disc Brake
Cylinder Slide Pin
Front Disc Brake
Cylinder Mounting LH
Front Disc Brake
Pad Support Plate
Disc brake grease Lithium soap base glycol grease
Non-reusable part
NVm (kgfVcm, ftVlbf)
: Specified torque Single Piston Type:
Anti Squeal
Shim No.1
Disc Brake
Pad Kit Front Anti Squeal
Shim No.1
Anti Squeal
Shim No.2
Anti Squeal
Shim No.2
Wear Indicator
8.3 (85, 74 in.Vlbf)
29.4 (300, 22)34.3 (350, 25)
34.3 (350, 25)
106.9 (1,090, 79)
106.9 (1,090, 79)
- BRAKEFRONT BRAKE
32-31
2465 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FRONT BRAKE
COMPONENTS