Mount LEXUS ES300 2005 Repair Manual

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.

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

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

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

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

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

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)

I31546
I31561
(A)
(B)
I31544
(E)
(C)(D)
- HEATER & AIR CONDITIONERCOOLER COMPRESSOR ASSY
55-41
2656 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
13. INSPECT COMPRESSOR OIL
(a) When replacing the compressor and magnetic clutch with new one, after gradually removing the refrig-
erant gas from the service valve, drain the following amount of oil from the new compressor and mag-
netic clutch before installation.
Standard:
(Oil capacity inside new compressor and magnetic clutch: 120 + 15 cc (4.1 + 0.51 fl.oz.) ) - (Re-
maining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be re-
moved when replacing)
NOTICE:

When checking the compressor oil level, observe the precautions on the cooler removal/instal-
lation.

Because compressor oil remains in the pipes of the vehicle, if a new compressor and magnetic
clutch is installed without removing some oil inside, the oil amount becomes too much, pre-
venting heat exchange in the refrigerant cycle and causing refrigerant failure.

If the remaining oil in the removed compressor and magnetic clutch is too small in volume,
check for oil leakage.

Be sure to use ND-OIL8 for compressor oil.
14. TEMPORARY TIGHTEN COMPRESSOR AND
MAGNETIC CLUTCH
(a) Temporarily the compressor and magnetic clutch with the
3 bolts.
15. FULLY TIGHTEN COMPRESSOR AND MAGNETIC
CLUTCH
(a) Tighten the compressor and magnetic clutch with the bolt
(A) and bolt (B).
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
(b) Install the cooler compressor bracket with the 2 bolts and
nut.
Torque:
25 NVm (250 kgfVcm, 18 ftVlbf) (Bolt (C))
25 NVm (250 kgfVcm, 18 ftVlbf) (Nut (D))
18 NVm (184 kgfVcm, 13 ftVlbf) (Bolt (E))

I31562
(F)
I31542
I31543
55-42
- HEATER & AIR CONDITIONERCOOLER COMPRESSOR ASSY
2657 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Tighten the compressor and magnetic clutch with the bolt
(F).
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
(d) Connect the connector.
16. INSTALL COOLER REFRIGERANT SUCTION HOSE
NO.1
(a) Remove the attached vinyl tape from the hose.
(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 NVm (100 kgfVcm, 87 in.Vlbf)
17. INSTALL COOLER REFRIGERANT DISCHARGE
HOSE NO.1
(a) Remove the attached vinyl tape from the hose.
(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 NVm (100 kgfVcm, 87 in.Vlbf)
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)

55-48
- HEATER & AIR CONDITIONERCOOLER CONDENSER ASSY
2663 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
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)