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55-1

HEATER & AIR CONDITIONER - AIR CONDITIONING SYSTEM

AIR CONDITIONING SYSTEM


550BQ-01

PRECAUTION

1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED


AREA OR NEAR AN OPEN FLAME
2. ALWAYS WEAR EYE PROTECTION

AC2810

3. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN


YOUR EYES OR ON YOUR SKIN
If liquid refrigerant gets in your eyes or on your skin.
(a) Wash the area with lots of cool water.
CAUTION:
Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin.
(c) Go immediately to a physician or hospital for professional
AC2811 treatment.
4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED
FLAME
5. BE CAREFUL NOT TO DROP CONTAINER AND NOT
TO APPLY PHYSICAL SHOCKS TO IT

6. DO NOT OPERATE COMPRESSOR WITHOUT


Wrong Okay
ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM
If there is not enough refrigerant in the refrigerant system oil lu-
LO HI LO HI brication will be insufficient and compressor burnout may occur,
so take care to avoid this, necessary care should be taken.
7. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE
WHILE COMPRESSOR IS OPERATING
If the high pressure valves opened, refrigerant flows in the re-
N11084 verse direction and could cause the charging cylinder to rup-
ture, so open and close the only low pressure valve.
8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH
REFRIGERANT
If refrigerant is overcharged, it causes problems such as insuffi-
cient cooling, poor fuel economy, engine overheating etc.

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2616


55-2
HEATER & AIR CONDITIONER - REFRIGERANT

REFRIGERANT
550D4-02

ON-VEHICLE INSPECTION

1. INSPECT REFRIGERANT VOLUME


(a) Observe the sight glass on the cooler refrigerant liquid
pipe A.
Test conditions:
Sight Glass
 Running engine at 1,500 rpm
 Blower speed control switch at HI
 A/C switch ON
 Temperature control dial at MAX. COOL
I31521  Fully open the doors

Item Symptom Amount of refrigerant Corrective Actions


(1) Check for gas leakage and repair if nec-
1 Bubbles present Insufficient* essary
(2) Add refrigerant until bubbles disappear
2 No bubbles present None, insufficient or too much Refer 3 and 4
(1) Check for gas leakage with gas leak de-
No temperature difference between com-
3 Empty or nearly empty tector and repair if necessary
pressor inlet and outlet
(2) Add refrigerant until bubbles disappear
Considerable temperature difference be-
4 Correct or too much Refer to 5 and 6
tween compressor inlet and outlet.

(1) Discharge refrigerant


Immediately after air conditioning is turned
5 Too much (2) Remove air and supply proper amount or
off, refrigerant clear
purified refrigerant
Immediately after air conditioning is turned
6 off, refrigerant foams and then becomes Correct -
clear
*: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling
is sufficient.

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2617


55-3
HEATER & AIR CONDITIONER - REFRIGERANT

2. INSPECT REFRIGERANT PRESSURE WITH MAN-


IFOLD GAUGE SET
(a) This is a method in witch the trouble is located by using
a manifold gauge set. Read the manifold gauge pressure
when the these conditions are established.
Test conditions:
 Temperature at the air inlet with the switch set
at RECIRC is 30 - 35 C (86 - 95 F)
 Engine running at 1,500 rpm
 Blower speed control switch at HI position
 Temperature control dial at COOL position
 A/C switch ON
 Fully open doors

(1) Normally functioning refrigeration system.


Gauge reading:
Low pressure side:
0.15 - 0.25 MPa (1.5 - 2.5 kgf/cm2)
High pressure side:
1.37 - 1.57 MPa (14 - 16 kgf/cm2)

E50573

(2) Moisture present in refrigeration system.


Condition : Periodically cools and then fails to cool

I22117

Symptom Probable cause Diagnosis Remedy


Moisture in refrigerating system  Drier in oversaturected state (1) Replace condenser
During operation, pressure on low freezes at expansion valve orifice  Moisture in refrigerating system (2) Remove moisture in cycle by
pressure side sometimes become causing a temporary stop of cycle, freezes at expansion valve orifice repeatedly evacuating air
a vacuum and sometime normal however, when it melts, normal and blocks circulation of refriger- (3) Supply proper amount of new
state is restored. ant refrigerant

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2618


55-4
HEATER & AIR CONDITIONER - REFRIGERANT

(3) Insufficient cooling

Condition: Cooling system does not function effectively.

I22118

Symptom Probable cause Diagnosis Corrective Actions


(1) Check for gas leakage and re-
pair if necessary
 Pressure low on both low and (2) Supply proper amount of new
high pressure sides refrigerant
Gas leakage in refrigeration sys-  Insufficient refrigerant
 Bubbles seen thought sight glass (3) If indicated pressure value is
tem  Refrigerant leaking
continuously close to a 0 when connected to
 Insufficient cooling performance gauge, create the vacuum after in-
specting and repairing location of
leak

(4) Poor circulation of refrigerant

Condition: Cooling system close not function effectively.

I22119

Symptom Probable cause Diagnosis Corrective Action


 Pressure low on both low and
high pressure sides Refrigerant flow obstructed by dirt
Receiver clogged Replace condenser
 Frost on pipe from condenser to in receiver
unit

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2619


55-5
HEATER & AIR CONDITIONER - REFRIGERANT

(5) Refrigerant does not circulate

Condition: Cooling system does not function. (Sometimes it way function)

I22120

Symptom Probable cause Diagnosis Corrective Actions


(1) Check expansion valve
(2) Clean out dirt in expansion
 Vacuum indicated on low pres-
 Refrigerant flow obstructed by valve by air blowing
sure side, very low pressure indi-
moisture or dirt in refrigerating sys- (3) Replace condenser
cated on high pressure side
tem Refrigerant does not circulate (4) Evaporate air and supply prop-
 Frost or dew seen on piping be-
 Refrigerant flow obstructed by er amount of new refrigerant.
fore and after receiver/ drier or ex-
gas leaked from expansion valve (5) For gas leakage from expan-
pansion valve
sion valve, replace expansion
valve

(6) Refrigerant overcharged or insufficient cooling of


condenser

Condition: Cooling system does not function effectively.

I22121

Symptom Probable cause Diagnosis Remedy


(1) Clean condenser
 Excessive refrigerant in
 Pressure too high on both low (2) Check cooling fan with cooling
 Unable to develop sufficient per- cycletoo much refrigerant sup-
and high pressure sides fan motor operation
formance due to excessive use of plied
 No sir bubbles seen through the (3) If (1) and (2) are in normal
refrigerating system  Condenser cooling
sight glass even when the engine state, check amount of refrigerant
 Insufficient cooling of condenser insufficientcondenser fins
rpm is lowered and supply proper amount of re-
clogged at cooling fan
frigerant

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2620


55-6
HEATER & AIR CONDITIONER - REFRIGERANT

(7) Air present in refrigeration system

Condition: Cooling system does not function.

NOTE : These gauge indica-


tions are shown when the
refrigerating system has
been opens and the refriger-
ant charged without vacuum
purging. I22122

Symptom Probable cause Diagnosis Corrective Actions


 Pressure too high on both low (1) Check compressor oil to see if
and high pressure sides  Air present in refrigerating sys- it is see if it is dirty or insufficient
 The low pressure piping too hot Air entered in refrigerating system tem (2) Evacuate air and supply new
to the touch  Insufficient vacuum purging refrigerant
 Bubbles seen through sight glass

(8) Expansion valve improperly

Condition: Refrigerant functions insufficient.

I22123

Symptom Probable cause Diagnosis Corrective Actions


 Pressure too high on both low  Excessive refrigerant in low
and high pressure sides pressure piping
Trouble in expansion valve Check expansion valve
 Frost or large amount of dew on  Expansion valve opened too
piping on low pressure side wide

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2621


55-7
HEATER & AIR CONDITIONER - REFRIGERANT

(9) Defective compression compressor

Condition : Refrigerant is not effective.

I22124

Symptom Probable cause Diagnosis Corrective Actions


 Pressure too high on low high
 Compression failure
pressure sides
Internal leak in compressor  Leakage from valve damaged or Repair or replace compressor
 Pressure too low to on high pres-
broken sliding parts
sure side

Gauge readings (Reference)

Pressure on low pressure side


MPa (kgf/cm2)

0.5 (5.0)

Blower HI Zone
0.4 (4.0)

1.06 (10.9)

0.3 (3.0)
0.27 (2.85)
1.2 (12.3)
0.22 (2.25) Blower LO Zone
0.2 (2.0) 0.2 (2.1)
1.25 (12.8)
0.14 (1.5)
1.32 (13.5)

Pressure on HI
0.5 (5.0) 1.0 (10.0) 1.5 (15.0) 2.0 (20.0) pressure side
MPa (kgf/cm2)

I30081

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2622


55-8
HEATER & AIR CONDITIONER - REFRIGERANT
550D5-02

REPLACEMENT
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
(a) Turn the A/C switch ON.
(b) Operating the cooler compressor at the engine rpm of approx. 1,000 for 5 to 6 min., circulate the refrig-
erant and collect compressor oil remaining in each component into the cooler compressor as much
as possible.
(c) Stop the engine.
(d) Let the refrigerant gas out.
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070,
07117-88080)
2. CHARGE REFRIGERANT
(a) Using a vacuum pump, perform a vacuum pumping.
(b) Charge refrigerant, HFC-134a (R134a).
Standard: 550  50 g (19.37  1. 76 oz.)
SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050,
07117-88060, 07117-88070, 07117-88080)

Amount to be charged
Add. 100g Mean
value
in proper
range

 50 g (1. 76 oz.)
High Over charged
Pressure

Point where
bubbles disappear

Refrigerant Amount
Sub-cool system
I30082

3. WARM UP ENGINE
4. INSPECT LEAKAGE OF REFRIGERANT

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2623


55-9
HEATER & AIR CONDITIONER - REFRIGERANT LINE

REFRIGERANT LINE
550D6-02

COMPONENTS

Cooler Refrigerant Liquid Pipe A

5.4 (55, 49 in.lbf)

9.8 (100, 87 in.lbf)


9.8 (100, 87 in.lbf)
Cooler Refrigerant Suction Hose No. 1

9.8 (100, 87 in.lbf)

5.4 (55, 49 in.lbf)

Cooler Refrigerant Discharge Hose No. 1

Nm (kgfcm, ftlbf) : Specified torque


I31620

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2624


55-10 HEATER & AIR CONDITIONER - V (COOLER COMPRESSOR TO CRANKSHAFT
PULLEY) BELT NO.1

V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY)


BELT NO.1
550D7-02

REPLACEMENT
Bolt B 1. REMOVE V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
Bolt C
(a) Loosen the bolt C.
(b) Loosen the bolt A.
(c) Loosen the bolt B and remove the cooler V belt No. 1.
Bolt A

I30370

2. INSTALL V (COOLER COMPRESSOR TO


CRANKSHAFT PULLEY) BELT NO.1
(a) Temporarily install the cooler V belt No. 1 as illustrated.

I30370

Bolt B 3. ADJUST V (COOLER COMPRESSOR TO


CRANKSHAFT PULLEY) BELT NO.1
(a) Apply drive belt tension by turning the bolt B.
Drive belt tension:
Measuring New Belt: 165  27 lbf
Position Used belt: 88  22 lbf
HINT:
 New belt refers to a belt which has been used less than
I30370 5 minutes on a running engine.
 Used belt refers to a belt which has been used on a run-
ning engine for 5 minutes or more.
DENSO Boroughs  After installing the drive belt, check that it fits properly in
the ribbed grooves.

N01881

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2625


HEATER & AIR CONDITIONER - V (COOLER COMPRESSOR TO CRANKSHAFT 55-1 1
PULLEY) BELT NO.1

 Check that the drive belt fits properly in the ribbed


grooves.

Wrong Correct

CH0086

4. FULLY TIGHTEN V (COOLER COMPRESSOR TO


CRANKSHAFT PULLEY) BELT NO.1
Bolt C
(a) Tighten the bolt A.
Torque: 17.5 Nm (178 kgfcm, 12 ftlbf)
(b) Tighten the bolt C.
Bolt A Torque: 58 Nm (591 kgfcm, 43 ftlbf)

I30370

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2626


55-12
HEATER & AIR CONDITIONER - AIR CONDITIONER CONTROL ASSEMBLY

AIR CONDITIONER CONTROL ASSEMBLY


550D8-02

COMPONENTS

Heater Control Housing Sub-assy

Air Conditioning Control Bulb

Heater Control Housing

I31621

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55-13
HEATER & AIR CONDITIONER - AIR CONDITIONER CONTROL ASSEMBLY
550D9-02

OVERHAUL
HINT:
COMPONENTS: See page 55-12
1. REMOVE AIR CONDITIONER CONTROL ASSEMBLY (See page 71-1 1)

2. REMOVE HEATER CONTROL HOUSING SUB-ASSY


(a) Remove the 4 screws.
(b) Release the 4 fitting claws, disconnect the heater control
housing sub-assy.

4 Claws
I31622

(c) Disconnect the connect, remove the heater control hous-


ing sub-assy.

I31623

3. REMOVE AIR CONDITIONING CONTROL BULB


(a) Remove the air conditioning control bulb.

I31626

4. REMOVE HEATER CONTROL HOUSING


(a) Release the 8 fitting claws, remove the heater control
housing.

8 Claws
I31627

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55-14
HEATER & AIR CONDITIONER - AIR CONDITIONER CONTROL ASSEMBLY

B A B 5. INSTALL AIR CONDITIONING CONTROL BULB


(a) Install the air conditioning control bulb to the air condition-
er panel sub-assy.
Bulb position:
Position Part No.
A 90010 - 03048
B 90010 - 03049

B I31626

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

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55-15
HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY

AIR CONDITIONING RADIATOR ASSY


550DA-02

COMPONENTS

Instrument Panel Reinforcement

Instrument Panel
Brace Sub-assy No. 2
Instrument Finish Panel Retainer Lower
20 (203, 14)

Instrument Panel
Brace Sub-assy

9.8 (100, 87 in.lbf)


Console Box Duct No. 1
Air Duct Rear No. 1
Air Duct Rear No. 2
1.5 (15, 12 in.lbf)

Defroster Nozzle
Assy Lower

1.5 (15, 12 in.lbf)


 O-ring

Piping Clamp
Blower Assy

 O-ring 1.5 (15, 12 in.lbf)

Heater To Foot Duct No. 3

Heater To Foot Duct No. 1

Nm (kgfcm, ftlbf) : Specified torque 1.5 (15, 12 in.lbf)


Compressor Oil ND-OIL 8 or equivalent
 Non-reusable part Air Conditioning Radiator Assy I31632

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2630


55-16
HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY

Air Conditioning Tube Assy

 Packing
Cooler Expansion Valve
3.5 (35, 30 in.lbf)

Cooler Evaporator Sub-assy No. 1

 O-ring

Cooler Thermistor No. 1

Mode Damper Servo Sub-assy

Air Mix Damper Servo


Sub-assy

Air Mix Damper Servo


Sub-assy

Piping Clamp

Heater Radiator Unit Sub-assy

Nm (kgfcm, ftlbf) : Specified torque


Compressor Oil ND-OIL 8 or equivalent
 Non-reusable part I31633

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2631


55-17
HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY
550DB-02

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.


Push Pull 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.

SST
Release
Lever I03839

(d) Disconnect the cooler refrigerant suction hose No. 1.


Disconnect the
tube using hand Screw NOTICE:
Driver  Do not use tools like screwdriver to remove the tube.
 Cap the open fittings immediately to keep moisture or
dirt out of the system.

I06919

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.

I31522

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2632


55-18
HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY

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.

I31636

8. REMOVE AIR DUCT REAR NO.2


(a) Remove the 2 screws, bolt and nut.
(b) Remove the air duct rear No. 2.

I31637

9. REMOVE CONSOLE BOX DUCT NO.1


(a) Remove the clip and console box duct No. 1.

I31497

10. DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY


11. REMOVE WINDSHIELD WIPER RELAY ASSY
12. REMOVE HEADLAMP LEVELING ECU ASSY

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

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55-19
HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY

13. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY


NO.1
(a) Remove the bolt and earth wire.

I31766

(b) Release the 2 clamps.

2 Clamps I31581

(c) Remove the bolt and screw.


(d) Remove the nut and instrument panel brace sub-assy
No. 1.

I31501

14. REMOVE INSTRUMENT FINISH PANEL RETAINER


LOWER
(a) Remove the 2 bolts and instrument finish retainer lower.

I31502

15. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY


NO.2
(a) Remove the 2 clamps, nut and passenger side junction
block.

2 Clamps I31768

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

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55-20
HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY

(b) Remove the 2 bolts and 2 earth wires.

I31767

(c) Remove the 2 nuts, bolt and instrument panel brace sub-
assy No. 2.

I31504

16. REMOVE HEATER TO FOOT DUCT NO.3


(a) Remove the clip and heater to foot duct No. 3.

I31499

17. REMOVE HEATER TO FOOT DUCT NO.1


(a) Remove the clip and heater to foot duct No. 1.

I31500

18. DISCONNECT STEERING COLUMN ASSY


(a) Remove the 3 nuts and driver side junction block.

I31505

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2635


55-21
HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY

(b) Remove the 2 nuts and steering side connector block.

I31577

(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.

2 Clamps I31506

10 Clamps I31769

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2636


55-22
HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY

(b) Remove the 3 nuts, disconnect the 3 earth wires.

I31770

(c) Remove the 3 caps, 7 bolts and instrument panel rein-


forcement.

I31771

20. REMOVE BLOWER ASSY


(a) Disconnect the connectors.
(b) Remove the screw, clamp and blower connector holder.

Clamp I31563

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55-23
HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY

(c) Disconnect the 6 clamps and the wire harness.

6 Clamps I31772

(d) Remove the 2 screws, 2 nuts and blower assy.

I31509

21. REMOVE DEFROSTER NOZZLE ASSY LOWER


(a) Release the 4 fitting claws, remove the defroster nozzle
assy lower.

4 Claws I31510

22. REMOVE AIR CONDITIONING RADIATOR ASSY


(a) Remove the 2 nuts and air conditioning radiator assy.

I31511

23. REMOVE MODE DAMPER SERVO SUB-ASSY


(a) Remove the 3 screws and mode damper servo sub-assy.

I31512

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2638


55-24
HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY

24. REMOVE AIRMIX DAMPER SERVO SUB-ASSY


(a) LH side:
Remove the 3 screws and air mix damper servo sub-
assy.

I31514

(b) RH side:
Remove the 3 screws and air mix damper servo sub-
assy.

I31638

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.

2 Claws I31513

26. REMOVE AIR CONDITIONING TUBE ASSY


(a) Remove the packing.

I31515

(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.

I31516

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2639


55-25
HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY

27. REMOVE COOLER EXPANSION VALVE


(a) Remove the cooler expansion valve from the cooler evap-
orator sub-assy No. 1.

I31517

28. REMOVE COOLER THERMISTOR NO.1

29. REMOVE COOLER EVAPORATOR SUB-ASSY NO.1


(a) Release the fitting claw, remove the 3 screws and air duct
sub-assy .

Claw I31518

(b) Release the 4 fitting claws, remove the air duct sub-assy.

4 Claws I31639

(c) Remove the 11 screws and heater case LH.


(d) Remove the cooler evaporator sub-assy No. 1 from the
heater case RH.

I31640

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55-26
HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY

(e) Remove the 2 O-rings from the cooler evaporator sub-


assy No. 1.

I31520

30. INSTALL COOLER EVAPORATOR SUB-ASSY NO.1


(a) Apply compressor oil to the contact surfaces of 2 new O-
rings and the cooler expansion valve and install them.
Compressor oil: ND-OIL 8 or equivalent

I31520

(b) Install the cooler evaporator sub-assy No. 1 to the heater


case RH.
(c) Install the heater case LH with the 11 screws.

I31640

(d) Install the air duct sub-assy.

4 Claws I31639

(e) Install the air duct sub-assy with the 3 screws.

Claw I31518

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

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55-27
HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY

31. INSTALL COOLER EXPANSION VALVE


(a) Install the cooler expansion valve to the cooler evaporator
No. 1.

I31517

32. INSTALL AIR CONDITIONING TUBE ASSY


(a) Apply compressor oil to the contact surfaces of 2 new O-
rings and the air conditioning tube assy and install them.
Compressor oil: ND-OIL 8 or equivalent
(b) Using a hexagon wrench 4 mm (0.16 in.), install the air
conditioner tube assy and 2 hexagon bolts to the cooler
evaporator sub-assy No. 1.
Torque: 3.5 Nm (35 kgfcm, 30 in.lbf)
I31516

(c) Install the packing.


HINT:
Securely attach so that the gap in the packing will not be mode.

I31515

33. INSTALL AIR CONDITIONING RADIATOR ASSY


(a) Install the air conditioning radiator assy with the 2 nuts.
Torque: 1.5 Nm (15 kgfcm, 12 in.lbf)

I31511

34. INSTALL DEFROSTER NOZZLE ASSY LOWER


(a) Install the defroster nozzle assy lower.
NOTICE:
After locating the pin (1) in the illustration, install (2), then
(2) (2) (3).
(1)

(3) (3)
I31552

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2642


55-28
HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY

35. INSTALL BLOWER ASSY


(a) Install the blower assy with the 2 screws and 2 nuts.
Torque: 1.5 Nm (15 kgfcm, 12 in.lbf)

I31509

(b) Install the 6 clamps, connect the wire harness.

6 Clamps I31772

(c) Install the blower connector holder with the screw.


(d) Connect the connectors.

36. INSTALL INSTRUMENT PANEL REINFORCEMENT


(a) Install the instrument panel reinforcement with the 7 bolts
and 3 caps.
Clamp I31563 Torque: 20 Nm (203 kgfcm, 14 ftlbf) (Bolt A)

(A)
I31771

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55-29
HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY

(b) Install the 3 earth wires with the 3 nuts.


Torque: 8.4 Nm (85 kgfcm, 73 in.lbf)

I31770

(c) Install the 10 clamps, connect the wire harness.

10 Clamps I31769

37. INSTALL STEERING COLUMN ASSY


(a) Install the steering column assy with the 3 bolts.
(b) Install the 2 clamps.

2 Clamps I31506

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HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY

(c) Install the steering side connector block with the 2 nuts.

I31577

(d) Install the driver side junction block with the 3 nuts.
Torque: 8.4 Nm (85 kgfcm, 73 in.lbf)

I31505

38. INSTALL INSTRUMENT PANEL BRACE SUB-ASSY


NO.2
(a) Install the instrument panel brace sub-assy No. 2 with the
2 nuts and bolt.

I31504

(b) Install the 2 earth wires with the 2 bolts.


Torque: 8.4 Nm (85 kgfcm, 73 in.lbf)

I31767

(c) Install the passenger side junction block with the nut and
2 clamps.
Torque: 8.4 Nm (85 kgfcm, 73 in.lbf)

2 Clamps I31768

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HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY

39. INSTALL INSTRUMENT FINISH PANEL RETAINER


LOWER
(a) Install the instrument finish panel retainer lower with the
2 bolts.

I31502

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 Nm (100 kgfcm, 87 in.lbf) (Screw)

I31501

(c) Install the 2 clamps.

2 Clamps I31581

(d) Install the earth wire with the bolt.


Torque: 8.4 Nm (85 kgfcm, 73 in.lbf)

I31766

41. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See page 71-1 1)

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HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY

42. INSTALL COOLER REFRIGERANT SUCTION HOSE


Connect Wrong NO.1
Gap (a) Lubricate new O-ring with compressor oil and install them
to the hose.
Compressor oil: ND-OIL 8 or equivalent
(b) Install the cooler refrigerant suction hose No.1 and piping
clamp.
HINT:
I06878 After connection, check the fitting for claw of the piping clamp.

43. INSTALL COOLER REFRIGERANT LIQUID PIPE A


HINT:
Install in the same way as the cooler refrigerant suction hose No. 1.
44. ADD COOLANT (See page 16-9 )
45. 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.)
46. WARM UP ENGINE
47. CHECK ENGINE COOLANT LEAK (See page 16-9 )
48. INSPECT LEAKAGE OF REFRIGERANT (See page 55-8 )

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HEATER & AIR CONDITIONER - BLOWER ASSY

BLOWER ASSY
550DC-02

COMPONENTS

1.5 (15, 12 in.lbf)

Blower Assy

1.5 (15, 12 in.lbf)

Heater To Foot Duct No. 1

Recirculation Damper Servo Sub-assy


Cowl Wire No. 2

Air Refiner Element

Blower Motor Control

Blower w/ fan Motor Sub-assy

Instrument Panel No. 3 Wire

Nm (kgfcm, ftlbf) : Specified torque


I31634

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HEATER & AIR CONDITIONER - BLOWER ASSY
550DD-02

OVERHAUL
HINT:
COMPONENTS: See page 55-33
1. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See page 71-1 1)
2. REMOVE HEATER TO FOOT DUCT NO.1 (See page 55-17 )
3. REMOVE BLOWER ASSY (See page 55-17 )
4. REMOVE AIR REFINER ELEMENT

5. REMOVE COWL WIRE NO.2


(a) Remove the clamp and cowl wire No. 2.

Clamp I31523

6. REMOVE RECIRCULATION DAMPER SERVO


SUB-ASSY
(a) Remove the 3 screws and recirculation damper servo
sub-assy .

I31524

7. REMOVE INSTRUMENT PANEL NO.3 WIRE


(a) Disconnect the connectors, remove the 2 clamps and
instrument panel No. 3 wire.

2 Clamps I31528

8. REMOVE BLOWER MOTOR CONTROL


(a) Remove the 2 screws and blower motor control.

I31525

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HEATER & AIR CONDITIONER - BLOWER ASSY

9. REMOVE BLOWER W/FAN MOTOR SUB-ASSY


(a) Remove the 3 screws and blower w/fan motor sub-assy.

I31527

10. INSTALL BLOWER ASSY (See page 55-17 )


11. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See page 71-1 1)

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HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY

COOLER COMPRESSOR ASSY


550DE-02

COMPONENTS

Cooler Compressor Bracket

Magnet Clutch Assy

Cooler Compressor Assy

 Snap Ring

 Snap Ring

18 (184, 13) Magnet Clutch Washer

Nm (kgfcm, ftlbf) : Specified torque


 Non-reusable part I31774

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HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY
550DF-02

REPLACEMENT
HINT:
COMPONENTS: See page 55-36
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 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 55-10 )
3. REMOVE GENERATOR ASSY (See page 19-21 )

4. DISCONNECT COOLER REFRIGERANT DISCHARGE


HOSE NO.1
(a) Remove the nut and disconnect the cooler refrigerant dis-
charge hose No. 1.
(b) Remove the O-ring from the cooler refrigerant discharge
hose No. 1.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
I31543 to prevent moisture and foreign matter from entering.

5. DISCONNECT COOLER REFRIGERANT SUCTION


HOSE NO.1
(a) Remove the nut and disconnect the cooler refrigerant
suction hose No. 1.
(b) Remove the O-ring from the cooler refrigerant suction
hose No. 1.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
I31542 to prevent moisture and foreign matter from entering.

6. REMOVE COMPRESSOR AND MAGNETIC CLUTCH


(a) Disconnect the connector and clamp.
(b) Remove the 2 bolts, nut and cooler compressor bracket.

I31544

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HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY

(c) Remove the 3 bolts and compressor and magnetic clutch.

I31546

7. REMOVE COOLER COMPRESSOR BRACKET


(a) Remove the screw, earth wire and cooler compressor
bracket.

E58517

8. REMOVE MAGNET CLUTCH ASSY


(a) Remove the bolt and bracket.
(b) Place the compressor and magnetic clutch in vise.

I30363

(c) Using a vise pliers, hold the magnet clutch hub.


(d) Remove the bolt, magnet clutch hub and magnet clutch
washer.

I31547

(e) Using a snap ring expander, remove the snap ring and
magnet clutch rotor.
(f) Disconnect the connector.

E37091

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HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY

(g) Using a snap ring expander, remove the snap ring and
magnet clutch starter.

I30400

9. REMOVE COOLER COMPRESSOR ASSY

10. INSTALL MAGNET CLUTCH ASSY


(a) Matching the parts shown in the illustration, install the
magnet clutch starter.

I30631

(b) Using a snap ring expander, install a new snap ring with
the chamfered side facing up.
(c) Connect the connector.

I30400

(d) Using a snap ring expander, install the magnet clutch ro-
tor and a new snap ring with the chamfered side facing up.
(e) Install the magnet clutch washer and magnet clutch hub.
NOTICE:
Do not change the combination of the magnet clutch wash-
ers used before disassembly.

I31582

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HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY

(f) Using a vise pliers, hold the magnet clutch hub and install
the bolt.
Torque: 18 Nm (184 kgfcm, 13 ftlbf)

I31548

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.)
I30369 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.

I30363

12. INSTALL COOLER COMPRESSOR BRACKET


(a) Install the earth wire and cooler compressor bracket with
the screw.

E58517

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HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY

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.

I31546

15. FULLY TIGHTEN COMPRESSOR AND MAGNETIC


CLUTCH
(a) Tighten the compressor and magnetic clutch with the bolt
(A) and bolt (B).
(A) Torque: 25 Nm (250 kgfcm, 18 ftlbf)

(B) I31561

(b) Install the cooler compressor bracket with the 2 bolts and
(E) nut.
Torque:
25 Nm (250 kgfcm, 18 ftlbf) (Bolt (C))
(D) 25 Nm (250 kgfcm, 18 ftlbf) (Nut (D))
18 Nm (184 kgfcm, 13 ftlbf) (Bolt (E))

(C)
I31544

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HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY

(c) Tighten the compressor and magnetic clutch with the bolt
(F).
Torque: 25 Nm (250 kgfcm, 18 ftlbf)
(d) Connect the connector.

16. INSTALL COOLER REFRIGERANT SUCTION HOSE


(F)
NO.1
(a) Remove the attached vinyl tape from the hose.
I31562 (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 Nm (100 kgfcm, 87 in.lbf)

17. INSTALL COOLER REFRIGERANT DISCHARGE


HOSE NO.1
(a) Remove the attached vinyl tape from the hose.
I31542 (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 Nm (100 kgfcm, 87 in.lbf)

I31543

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 )

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HEATER & AIR CONDITIONER - COOLER CONDENSER ASSY

COOLER CONDENSER ASSY


550DG-02

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.

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HEATER & AIR CONDITIONER - COOLER CONDENSER ASSY
550DH-02

COMPONENTS

Air Cleaner Inlet No. 1

Air Cleaner Inlet Assy

Radiator Support Upper

Radiator Lower Air Deflector


Hood Lock Release Lever
Protector

9.8 (100, 85 in.lbf)


9.8 (100, 85 in.lbf)

 O-ring

 O-ring 5.4 (55, 47 in.lbf)

Cooler Condenser Assy

Cooler Dryer

Filter

 O-ring
Cap
12 (125, 9)

Nm (kgfcm, ftlbf) : Specified torque


Compressor oil ND-OIL 8 or equivalent
 Non-reusable parts I31635
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55-45
HEATER & AIR CONDITIONER - COOLER CONDENSER ASSY
550DI-02

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
I31538 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
I31539 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.

I31540

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HEATER & AIR CONDITIONER - COOLER CONDENSER ASSY

7. REMOVE COOLER DRYER


(a) Using hexagon wrench 10 mm (0.39 in.), remove the cap
and filter from the modulator.

10 mm
(0.39 in.)
Hexagon
Wrench
Modulator
I30086

(b) Remove the 2 O-rings from the cap.

E50132

E57114

(c) Using a needle nose pliers, remove the cooler dryer.

8. INSTALL COOLER DRYER


(a) Using a needle nose pliers, install the cooler dryer.

E50386

(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

E50132

(d) Using hexagon wrench 10 mm (0.39 in.), install the cap


to the condenser assy.
Torque: 12 Nm (125 kgfcm, 9 ftlbf)

10 mm
(0.39 in.)
Hexagon
Wrench
Modulator
I30086

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HEATER & AIR CONDITIONER - COOLER CONDENSER ASSY

9. INSTALL COOLER CONDENSER ASSY


(a) Install the cooler condenser assy with the 2 nuts.
Torque: 9.8 Nm (100 kgfcm, 85 in.lbf)

I31541

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 Nm (55 kgfcm, 47 in.lbf)

12. INSTALL COOLER REFRIGERANT DISCHARGE


HOSE NO.1
(a) Remove the attached vinyl tape from the tube and con-
I31539 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 Nm (55 kgfcm, 47 in.lbf)

I31538

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HEATER & AIR CONDITIONER - COOLER CONDENSER ASSY

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 )

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2663