2005 LEXUS ES300 service

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))

0103A-07
D25697

Oil Seal

O-ring
Oil Pump Drive Gear
Oil Pump Driven Gear
Stator Shaft Assy
x13
10 (100, 7)
Oil Seal Ring
N´m (kgf´cm, ft´lbf): Specified torque

Non-reusable part
- INTRODUCTIONHOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR
MANUAL01-1
1 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR
MANUAL
GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting
3. Final Inspection
(c) This manual explainsº Removing and Installing, Replacing,
Disassembling ,Instaling and Checking,
Adjustingº , butº Final inspectionº is omitted.
(d) The following essential operations are not written in this manual, however these operations must be
done in the practical situation.
(1) Operation with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX is provided as a section on the end of the book to guide you to the item to be
repaired.
3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) may be required, depending
on the repairing condition. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) Component drawing is placed as the section or title when necessary.
(b) Illustrations of the parts catalog are placed as theº disassembled parts drawingº so that it enables you
to understand the fitting condition of the components.
(c) Non-reusable parts, grease applied parts, precoated parts and tightening torque are specified in the
components drawing.
Example:

Illustration:
what to do and whereTask heading: what to do
Detailed text:
how to do task
Set part No.Component part No.
87. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing front inner race to the differential
case.
SST 09316-60011 (09316-00011)
Illustration:
what to do and whereTask heading: what to do
Detailed text:
how to do task
Set part No.Component part No.
87. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing front inner race to the differential
case.
SST 09316-60011 (09316-00011)
D26831
01-2- INTRODUCTIONHOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR
MANUAL
2 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Tightening torque, oil applying position, and non-reusable parts are described as important points in
the procedure.
NOTICE:
There are cases where such information can only be indicated by an illustration. In that case, all the
information such as torque, oil, etc are described in the illustration.
(e) Installing procedure of operation item is performed in the reverse order of the removing, and only the
important points are described.
(f) Only items with points are described in the procedure, and the operational portion and content are
placed using an illustration. In the explanations, details of the operational method, standard value and
notice are placed.
(g) There may be a case where the illustrations of similar models are used. In that case the details may
be different from the actual vehicle.
(h) The procedures are presented in a step-by-step format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary, and the text below provides detailed information. Impor-
tant specifications and warnings always stand out in bold type.
5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce-
dure to look up your specifications. The specifications are also found in the Service Specifications sec-
tion for a quick reference.
6. TERMS DEFINITION
CAUTIONIndicate the possibility of injury to you or other people.
NOTICEIndicate the possibility of damage to the components being repaired.
HINTProvide additional information to help you perform the repair efficiently.

0103C-05
01-6- INTRODUCTIONTERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
6 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ASSYAssembly
AT FAutomatic Transaxle Fluid
B3U/D Brake
C2Reverse Clutch
C3U/D Clutch
FIPGFormed In Place Gasket
O/DOverdrive
SSMSpecial Service Materials
SSTSpecial Service Tools
U/DUnderdrive
w/With
w/oWithout
1stFirst
2ndSecond

01-8- INTRODUCTIONTERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
8 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U) ISC
Idle Speed Control-
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure-
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Light
MSTManifold Surface temperature-
MVZManifold Vacuum Zone-
NVRAMNon-V olatile Random Access Memory-
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn-Board DiagnosticOn-Board Diagnostic (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Converter (OC), CC0
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module-
PNPPark/Neutral Position-
PROMProgrammable Read Only Memory-
PSPPower Steering Pressure-
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module-
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger Bypass-
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter-
SRIService Reminder Indicator-
SRTSystem Readiness Test-
STScan Tool-
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter
TCMTransmission Control ModuleTransmission ECU (Electronic Control Unit)
TPThrottle PositionThrottle Position
TRTransmission Range-
TVVThermal Vacuum ValveBimetallic Vacuum Switching Valve (BVSV)
Thermostatic Vacuum Switching Valve (TVSV)
TWCThree-W ay Catalytic ConverterThree-W ay Catalytic (TWC)
CC
RO
TWC+OCThree-W ay + Oxidation Catalytic ConverterCCR + CCO
VA FVolume Air FlowAir Flow Meter
VRVoltage RegulatorVoltage Regulator
VSSVehicle Speed SensorVehicle Speed Sensor (Read Switch Type)
WOTWide Open ThrottleFull Throttle

- PREPARATIONAUTOMATIC TRANSMISSION / TRANS
02-7
16 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
SSM (Special Service Materials)
08826-00090Seal Packing 1281,
THREE BOND 1281 or equivalent
(FIPG)
08833-00080Adhesive 1344
THREE BOND 1344
LOCTITE 242 or equivalent

030JK-02
V06821
Mark
Mark Class
Class
Hexagon head
bolt
Bolt
head No.4-
5-
6-
7-
8-
9-
10-
11 -4T
5T
6T
7T
8T
9T
10T
11 T
No mark
No mark Hexagon
flange bolt
w/ washer
hexagon bolt4T
4T
5T
6T
7T
8T Hexagon head
bolt
Hexagon
flange bolt
w/ washer
hexagon bolt
Hexagon head
bolt
Hexagon head
bolt2
Protruding
lines
2
Protruding
lines
3
Protruding
lines
4
Protruding
linesHexagon
flange bolt
w/ washer
hexagon bolt
Hexagon
flange bolt
w/ washer
hexagon bolt
Hexagon
flange bolt
w/ washer
hexagon bolt
Stud bolt
Welded bolt4
Protruding
lines
5
Protruding
lines
6
Protruding
lines
No mark
Grooved9T
10T
11 T
4T
6T
4T
- SERVICE SPECIFICATIONSSTANDARD BOLT FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL03-1
17 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
STANDARD BOLT FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
HOW TO DETERMINE BOLT STRENGTH

030JL-02
V00079
ClassDiameter
mmPitch
mmSpecified torque
Hexagon head bolt
Hexagon flange bolt
N´m kgf´cm
ft´lbf N´mkgf´cm
ft´lbf
in.´lbf
in.´lbf
in.´lbfin.´lbf
in.´lbf
in.´lbf 03-2
- SERVICE SPECIFICATIONSSTANDARD BOLT FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL
18 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
SPECIFIED TORQUE FOR STANDARD BOLTS