Air Conditioning System PDF

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.
Author: Date: 2617

55-3
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
Author: Date: 2618

55-4
(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
Author: Date: 2619

55-5
(5) Refrigerant does not circulate
Condition: Cooling system does not function. (Sometimes it way function)
I22120

(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
Author: Date: 2620

55-6
(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

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

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
Author: Date: 2621

55-7
(9) Defective compression compressor
Condition : Refrigerant is not effective.
I22124

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
Author: Date: 2622

55-8
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
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
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

(a) Temporarily install the cooler V belt No. 1 as illustrated.
I30370
Bolt B 3. ADJUST V (COOLER COMPRESSOR TO

(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
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

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
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
Author: Date: 2627

55-13
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
Author: Date: 2628

55-14
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
Author: Date: 2629

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
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
Author: Date: 2630

55-16
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

Compressor Oil ND-OIL 8 or equivalent
Non-reusable part I31633
Author: Date: 2631

55-17
550DB-02
OVERHAUL
HINT:
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
Author: Date: 2632

55-18
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
Author: Date: 2633

55-19
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
Author: Date: 2634

55-20
(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
Author: Date: 2635

55-21
(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
Author: Date: 2636

55-22
(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
Author: Date: 2637

55-23
(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
Author: Date: 2638

55-24
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
Author: Date: 2639

55-25
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
Author: Date: 2640

55-26
(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
Author: Date: 2641

55-27
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.
(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.
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
Author: Date: 2642

55-28
35. INSTALL BLOWER ASSY

(a) Install the blower assy with the 2 screws and 2 nuts.
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
Author: Date: 2643

55-29
(b) Install the 3 earth wires with the 3 nuts.

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
Author: Date: 2644

55-30
(c) Install the steering side connector block with the 2 nuts.
I31577
(d) Install the driver side junction block with the 3 nuts.
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.

I31767
(c) Install the passenger side junction block with the nut and
2 clamps.
2 Clamps I31768
Author: Date: 2645

55-31
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.

I31766
41. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See page 71-1 1)
Author: Date: 2646

55-32
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.
(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 )
Author: Date: 2647

55-33
HEATER & AIR CONDITIONER - BLOWER ASSY
BLOWER ASSY
550DC-02
COMPONENTS
1.5 (15, 12 in.lbf)
Blower Assy
1.5 (15, 12 in.lbf)
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

I31634
Author: Date: 2648

55-34
550DD-02
OVERHAUL
HINT:
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
Author: Date: 2649

55-35
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)
Author: Date: 2650

55-36
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

Non-reusable part I31774
Author: Date: 2651

55-37
550DF-02
REPLACEMENT
HINT:
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:
6. REMOVE COMPRESSOR AND MAGNETIC CLUTCH

(a) Disconnect the connector and clamp.
(b) Remove the 2 bolts, nut and cooler compressor bracket.
I31544
Author: Date: 2652

55-38
(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
Author: Date: 2653

55-39
(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
Author: Date: 2654

55-40
(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
Author: Date: 2655

55-41
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
Author: Date: 2656

55-42
(c) Tighten the compressor and magnetic clutch with the bolt
(F).
(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.
(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.
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.
(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.
I31543
18. INSTALL GENERATOR ASSY (See page 19-21 )

19. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 55-10 )
SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050,
07117-88060, 07117-88070, 07117-88080)
21. WARM UP ENGINE
Author: Date: 2657

55-43
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.
Author: Date: 2658

55-44
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)

Compressor oil ND-OIL 8 or equivalent
Non-reusable parts I31635
Author: Date: 2659

55-45
550DI-02
OVERHAUL
HINT:
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
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:
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
Author: Date: 2660

55-46
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.
E50132
(d) Using hexagon wrench 10 mm (0.39 in.), install the cap

to the condenser assy.
10 mm
(0.39 in.)
Hexagon
Wrench
Modulator
I30086
Author: Date: 2661

55-47
9. INSTALL COOLER CONDENSER ASSY

(a) Install the cooler condenser assy with the 2 nuts.
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.
(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.
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.
(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.
I31538
Author: Date: 2662

55-48

SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050,
07117-88060, 07117-88070, 07117-88080)
14. WARM UP ENGINE
Author: Date: 2663

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55-1

HEATER & AIR CONDITIONER - AIR CONDITIONING SYSTEM

AIR CONDITIONING SYSTEM

1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED

3. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN

6. DO NOT OPERATE COMPRESSOR WITHOUT

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2616

1. INSPECT REFRIGERANT VOLUME

Item Symptom Amount of refrigerant Corrective Actions

(1) Discharge refrigerant

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2617

2. INSPECT REFRIGERANT PRESSURE WITH MAN-

(1) Normally functioning refrigeration system.

(2) Moisture present in refrigeration system.

Symptom Probable cause Diagnosis Remedy

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2618

(3) Insufficient cooling

Condition: Cooling system does not function effectively.

Symptom Probable cause Diagnosis Corrective Actions

(4) Poor circulation of refrigerant

Condition: Cooling system close not function effectively.

Symptom Probable cause Diagnosis Corrective Action

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2619

(5) Refrigerant does not circulate

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

Symptom Probable cause Diagnosis Corrective Actions

(6) Refrigerant overcharged or insufficient cooling of

Condition: Cooling system does not function effectively.

Symptom Probable cause Diagnosis Remedy

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2620

(7) Air present in refrigeration system

Condition: Cooling system does not function.

NOTE : These gauge indica-

Symptom Probable cause Diagnosis Corrective Actions

(8) Expansion valve improperly

Condition: Refrigerant functions insufficient.

Symptom Probable cause Diagnosis Corrective Actions

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2621

(9) Defective compression compressor

Condition : Refrigerant is not effective.

Symptom Probable cause Diagnosis Corrective Actions

Gauge readings (Reference)

Pressure on low pressure side

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2622

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2623

Cooler Refrigerant Liquid Pipe A

5.4 (55, 49 in.lbf)

9.8 (100, 87 in.lbf)

9.8 (100, 87 in.lbf)

5.4 (55, 49 in.lbf)

Cooler Refrigerant Discharge Hose No. 1

Nm (kgfcm, ftlbf) : Specified torque

2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

Author: Date: 2624