LEXUS ES300 2005 Owner's Guide

I31502
I31501
I315812 Clamps
I31766
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55-31
2646 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
39. INSTALL INSTRUMENT FINISH PANEL RETAINER
LOWER
(a) Install the instrument finish panel retainer lower with the
2 bolts.
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 NVm (100 kgfVcm, 87 in.Vlbf) (Screw)
(c) Install the 2 clamps.
(d) Install the earth wire with the bolt.
Torque: 8.4 NVm (85 kgfVcm, 73 in.Vlbf)
41. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See page 71-1 1)

I06878
Connect
GapWrong 55-32
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
2647 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
42. INSTALL COOLER REFRIGERANT SUCTION HOSE
NO.1
(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:
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)

550DC-02
I31634NVm (kgfVcm, ftVlbf): Specified torque
1.5 (15, 12 in.Vlbf)
Blower Assy
1.5 (15, 12 in.Vlbf)
Recirculation Damper Servo Sub-assy
Air Refiner ElementCowl Wire No. 2 Heater To Foot Duct No. 1
Blower w/ fan Motor Sub-assy
Instrument Panel No. 3 Wire Blower Motor Control
- HEATER & AIR CONDITIONERBLOWER ASSY
55-33
2648 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BLOWER ASSY
COMPONENTS

550DD-02
I31523Clamp
I31524
I315282 Clamps
I31525
55-34
- HEATER & AIR CONDITIONERBLOWER ASSY
2649 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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.
6. REMOVE RECIRCULATION DAMPER SERVO
SUB-ASSY
(a) Remove the 3 screws and recirculation damper servo
sub-assy .
7. REMOVE INSTRUMENT PANEL NO.3 WIRE
(a) Disconnect the connectors, remove the 2 clamps and
instrument panel No. 3 wire.
8. REMOVE BLOWER MOTOR CONTROL
(a) Remove the 2 screws and blower motor control.

I31527
- HEATER & AIR CONDITIONERBLOWER ASSY
55-35
2650 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
9. REMOVE BLOWER W/FAN MOTOR SUB-ASSY
(a) Remove the 3 screws and blower w/fan motor sub-assy.
10. INSTALL BLOWER ASSY (See page 55-17)
11. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See page 71-1 1)

550DE-02
I31774
18 (184, 13)



Non-reusable part
NVm (kgfVcm, ftVlbf): Specified torque Magnet Clutch WasherSnap Ring Magnet Clutch Assy
Cooler Compressor Assy

Snap Ring
Cooler Compressor Bracket
55-36
- HEATER & AIR CONDITIONERCOOLER COMPRESSOR ASSY
2651 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
COOLER COMPRESSOR ASSY
COMPONENTS

550DF-02
I31543
I31542
I31544
- HEATER & AIR CONDITIONERCOOLER COMPRESSOR ASSY
55-37
2652 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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
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
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.

I31546
E58517
I30363
I31547
E37091
55-38
- HEATER & AIR CONDITIONERCOOLER COMPRESSOR ASSY
2653 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Remove the 3 bolts and compressor and magnetic clutch.
7. REMOVE COOLER COMPRESSOR BRACKET
(a) Remove the screw, earth wire and cooler compressor
bracket.
8. REMOVE MAGNET CLUTCH ASSY
(a) Remove the bolt and bracket.
(b) Place the compressor and magnetic clutch in vise.
(c) Using a vise pliers, hold the magnet clutch hub.
(d) Remove the bolt, magnet clutch hub and magnet clutch
washer.
(e) Using a snap ring expander, remove the snap ring and
magnet clutch rotor.
(f) Disconnect the connector.

I30400
I30631
I30400
I31582
- HEATER & AIR CONDITIONERCOOLER COMPRESSOR ASSY
55-39
2654 Author
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:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(g) Using a snap ring expander, remove the snap ring and
magnet clutch starter.
9. REMOVE COOLER COMPRESSOR ASSY
10. INSTALL MAGNET CLUTCH ASSY
(a) Matching the parts shown in the illustration, install the
magnet clutch starter.
(b) Using a snap ring expander, install a new snap ring with
the chamfered side facing up.
(c) Connect the connector.
(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.

I31548
I30369
I30363
E58517
55-40
- HEATER & AIR CONDITIONERCOOLER COMPRESSOR ASSY
2655 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(f) Using a vise pliers, hold the magnet clutch hub and install
the bolt.
Torque: 18 NVm (184 kgfVcm, 13 ftVlbf)
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.)
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.
12. INSTALL COOLER COMPRESSOR BRACKET
(a) Install the earth wire and cooler compressor bracket with
the screw.