LEXUS ES300 2005 Repair Manual
Page 1 of 969
550BQ-01
AC2810
AC2811
N11084
Wrong Okay
HI
LO HI LO
- HEATER & AIR CONDITIONERAIR CONDITIONING SYSTEM
55-1
2616 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
AIR CONDITIONING SYSTEM
PRECAUTION
1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED
AREA OR NEAR AN OPEN FLAME
2. ALWAYS WEAR EYE PROTECTION
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
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
ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM
If there is not enough refrigerant in the refrigerant system oil lu-
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-
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.
Page 2 of 969
550D4-02
I31521
Sight Glass
55-2
- HEATER & AIR CONDITIONERREFRIGERANT
2617 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REFRIGERANT
ON-VEHICLE INSPECTION
1. INSPECT REFRIGERANT VOLUME
(a) Observe the sight glass on the cooler refrigerant liquid
pipe A.
Test conditions:
Running engine at 1,500 rpm
Blower speed control switch at ºHIº
A/C switch ON
Temperature control dial at ºMAX. COOLº
Fully open the doors
ItemSymptomAmount of refrigerantCorrective Actions
1Bubbles presentInsufficient*
(1) Check for gas leakage and repair if nec-
essary
(2) Add refrigerant until bubbles disappear
2No bubbles presentNone, insufficient or too muchRefer 3 and 4
3No temperature difference between com-
pressor inlet and outletEmpty or nearly empty
(1) Check for gas leakage with gas leak de-
tector and repair if necessary
(2) Add refrigerant until bubbles disappear
4Considerable temperature difference be-
tween compressor inlet and outlet.Correct or too muchRefer to 5 and 6
5Immediately after air conditioning is turned
off, refrigerant clearToo much
(1) Discharge refrigerant
(2) Remove air and supply proper amount or
purified refrigerant
6
Immediately after air conditioning is turned
off, refrigerant foams and then becomes
clear
Correct-
*: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling
is sufficient.
Page 3 of 969
E50573
I22117
Condition : Periodically cools and then fails to cool
- HEATER & AIR CONDITIONERREFRIGERANT
55-3
2618 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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 ºHIº position
Temperature control dial at ºCOOLº 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/cm
2)
High pressure side:
1.37 - 1.57 MPa (14 - 16 kgf/cm
2)
(2) Moisture present in refrigeration system.
SymptomProbable causeDiagnosisRemedy
During operation, pressure on low
pressure side sometimes become
a vacuum and sometime normal
Moisture in refrigerating system
freezes at expansion valve orifice
causing a temporary stop of cycle,
however, when it melts, normal
state is restored. Drier in oversaturected state
Moisture in refrigerating system
freezes at expansion valve orifice
and blocks circulation of refriger-
ant(1) Replace condenser
(2) Remove moisture in cycle by
repeatedly evacuating air
(3) Supply proper amount of new
refrigerant
Page 4 of 969
I22118
Condition: Cooling system does not function effectively.
I22119
Condition: Cooling system close not function effectively. 55-4
- HEATER & AIR CONDITIONERREFRIGERANT
2619 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(3) Insufficient cooling
SymptomProbable causeDiagnosisCorrective Actions
Pressure low on both low and
high pressure sides
Bubbles seen thought sight glass
continuously
Insufficient cooling performance
Gas leakage in refrigeration sys-
tem Insufficient refrigerant
Refrigerant leaking
(1) Check for gas leakage and re-
pair if necessary
(2) Supply proper amount of new
refrigerant
(3) If indicated pressure value is
close to a 0 when connected to
gauge, create the vacuum after in-
specting and repairing location of
leak
(4) Poor circulation of refrigerant
SymptomProbable causeDiagnosisCorrective Action
Pressure low on both low and
high pressure sides
Frost on pipe from condenser to
unit
Refrigerant flow obstructed by dirt
in receiverReceiver cloggedReplace condenser
Page 5 of 969
I22120
Condition: Cooling system does not function. (Sometimes it way function)
I22121
Condition: Cooling system does not function effectively.
- HEATER & AIR CONDITIONERREFRIGERANT
55-5
2620 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(5) Refrigerant does not circulate
SymptomProbable causeDiagnosisCorrective Actions
Vacuum indicated on low pres-
sure side, very low pressure indi-
cated on high pressure side
Frost or dew seen on piping be-
fore and after receiver/ drier or ex-
pansion valve Refrigerant flow obstructed by
moisture or dirt in refrigerating sys-
tem
Refrigerant flow obstructed by
gas leaked from expansion valve
Refrigerant does not circulate
(1) Check expansion valve
(2) Clean out dirt in expansion
valve by air blowing
(3) Replace condenser
(4) Evaporate air and supply prop-
er amount of new refrigerant.
(5) For gas leakage from expan-
sion valve, replace expansion
valve
(6) Refrigerant overcharged or insufficient cooling of
condenser
SymptomProbable causeDiagnosisRemedy
Pressure too high on both low
and high pressure sides
No sir bubbles seen through the
sight glass even when the engine
rpm is lowered Unable to develop sufficient per-
formance due to excessive use of
refrigerating system
Insufficient cooling of condenser
Excessive refrigerant in
cycle"too much refrigerant sup-
plied
Condenser cooling
insufficient"condenser fins
clogged at cooling fan(1) Clean condenser
(2) Check cooling fan with cooling
fan motor operation
(3) If (1) and (2) are in normal
state, check amount of refrigerant
and supply proper amount of re-
frigerant
Page 6 of 969
I22122
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.
I22123
Condition: Refrigerant functions insufficient. 55-6
- HEATER & AIR CONDITIONERREFRIGERANT
2621 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(7) Air present in refrigeration system
SymptomProbable causeDiagnosisCorrective Actions
Pressure too high on both low
and high pressure sides
The low pressure piping too hot
to the touch
Bubbles seen through sight glass
Air entered in refrigerating system
Air present in refrigerating sys-
tem
Insufficient vacuum purging
(1) Check compressor oil to see if
it is see if it is dirty or insufficient
(2) Evacuate air and supply new
refrigerant
(8) Expansion valve improperly
SymptomProbable causeDiagnosisCorrective Actions
Pressure too high on both low
and high pressure sides
Frost or large amount of dew on
piping on low pressure side
Trouble in expansion valve
Excessive refrigerant in low
pressure piping
Expansion valve opened too
wide
Check expansion valve
Page 7 of 969
I22124
Condition : Refrigerant is not effective.
I30081
0.5 (5.0)
0.4 (4.0)
0.3 (3.0)
0.2 (2.0)MPa (kgf/cm
2) Pressure on low pressure side
Blower HI Zone
Blower LO Zone
MPa (kgf/cm
2) Pressure on HI
pressure side 0.5 (5.0) 1.0 (10.0) 1.5 (15.0) 2.0 (20.0)1.06 (10.9)
0.27 (2.85)
0.22 (2.25)
0.2 (2.1)
0.14 (1.5)1.2 (12.3)
1.25 (12.8)
1.32 (13.5)
- HEATER & AIR CONDITIONERREFRIGERANT
55-7
2622 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(9) Defective compression compressor
SymptomProbable causeDiagnosisCorrective Actions
Pressure too high on low high
pressure sides
Pressure too low to on high pres-
sure side
Internal leak in compressor
Compression failure
Leakage from valve damaged or
broken sliding parts
Repair or replace compressor
Gauge readings (Reference)
Page 8 of 969
550D5-02
I30082
Over charged Mean
value
in proper
range Add. 100g
High
Pressure
Refrigerant Amount Point where
bubbles disappear 50 g (1. 76 oz.) Amount to be charged
Sub-cool system 55-8
- HEATER & AIR CONDITIONERREFRIGERANT
2623 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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)
3. WARM UP ENGINE
4. INSPECT LEAKAGE OF REFRIGERANT
Page 9 of 969
550D6-02
I31620
Cooler Refrigerant Liquid Pipe A
Cooler Refrigerant Suction Hose No. 1
Cooler Refrigerant Discharge Hose No. 1
NVm (kgfVcm, ftVlbf) : Specified torque
5.4 (55, 49 in.Vlbf)
9.8 (100, 87 in.Vlbf)
5.4 (55, 49 in.Vlbf)
9.8 (100, 87 in.Vlbf)
9.8 (100, 87 in.Vlbf)
- HEATER & AIR CONDITIONERREFRIGERANT LINE
55-9
2624 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REFRIGERANT LINE
COMPONENTS
Page 10 of 969
550D7-02
I30370
Bolt C
Bolt ABolt B
I30370
I30370
Measuring
Position
Bolt B
N01881
DENSO Boroughs 55-10
- HEATER & AIR CONDITIONERV (COOLER COMPRESSOR TO CRANKSHAFT
PULLEY) BELT NO.1
2625 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY)
BELT NO.1
REPLACEMENT
1. REMOVE V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a) Loosen the bolt C.
(b) Loosen the bolt A.
(c) Loosen the bolt B and remove the cooler V belt No. 1.
2. INSTALL V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a) Temporarily install the cooler V belt No. 1 as illustrated.
3. ADJUST V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a) Apply drive belt tension by turning the bolt B.
Drive belt tension:
New Belt: 165 27 lbf
Used belt: 88 22 lbf
HINT:
ºNew beltº refers to a belt which has been used less than
5 minutes on a running engine.
ºUsed beltº refers to a belt which has been used on a run-
ning engine for 5 minutes or more.
After installing the drive belt, check that it fits properly in
the ribbed grooves.