LEXUS ES300 2005 Owner's Manual

I31577
I315062 Clamps
I3176910 Clamps
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55-21
2636 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Remove the 2 nuts and steering side connector block.
(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.

I31770
I31771
I31563Clamp 55-22
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
2637 Author
: Date
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Remove the 3 nuts, disconnect the 3 earth wires.
(c) Remove the 3 caps, 7 bolts and instrument panel rein-
forcement.
20. REMOVE BLOWER ASSY
(a) Disconnect the connectors.
(b) Remove the screw, clamp and blower connector holder.

I317726 Clamps
I31509
I315104 Claws
I31511
I31512
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55-23
2638 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Disconnect the 6 clamps and the wire harness.
(d) Remove the 2 screws, 2 nuts and blower assy.
21. REMOVE DEFROSTER NOZZLE ASSY LOWER
(a) Release the 4 fitting claws, remove the defroster nozzle
assy lower.
22. REMOVE AIR CONDITIONING RADIATOR ASSY
(a) Remove the 2 nuts and air conditioning radiator assy.
23. REMOVE MODE DAMPER SERVO SUB-ASSY
(a) Remove the 3 screws and mode damper servo sub-assy.

I31514
I31638
I315132 Claws
I31515
I31516
55-24
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
2639 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
24. REMOVE AIRMIX DAMPER SERVO SUB-ASSY
(a) LH side:
Remove the 3 screws and air mix damper servo sub-
assy.
(b) RH side:
Remove the 3 screws and air mix damper servo sub-
assy.
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.
26. REMOVE AIR CONDITIONING TUBE ASSY
(a) Remove the packing.
(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.

I31517
I31518Claw
I316394 Claws
I31640
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55-25
2640 Author
: Date
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
27. REMOVE COOLER EXPANSION VALVE
(a) Remove the cooler expansion valve from the cooler evap-
orator sub-assy No. 1.
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 .
(b) Release the 4 fitting claws, remove the air duct sub-assy.
(c) Remove the 11 screws and heater case LH.
(d) Remove the cooler evaporator sub-assy No. 1 from the
heater case RH.

I31520
I31520
I31640
I316394 Claws
I31518Claw 55-26
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
2641 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(e) Remove the 2 O-rings from the cooler evaporator sub-
assy No. 1.
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
(b) Install the cooler evaporator sub-assy No. 1 to the heater
case RH.
(c) Install the heater case LH with the 11 screws.
(d) Install the air duct sub-assy.
(e) Install the air duct sub-assy with the 3 screws.

I31517
I31516
I31515
I31511
I31552
(1)(2)(2)
(3)(3)
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55-27
2642 Author
: Date
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
31. INSTALL COOLER EXPANSION VALVE
(a) Install the cooler expansion valve to the cooler evaporator
No. 1.
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 NVm (35 kgfVcm, 30 in.Vlbf)
(c) Install the packing.
HINT:
Securely attach so that the gap in the packing will not be mode.
33. INSTALL AIR CONDITIONING RADIATOR ASSY
(a) Install the air conditioning radiator assy with the 2 nuts.
Torque: 1.5 NVm (15 kgfVcm, 12 in.Vlbf)
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
(3).

I31509
I317726 Clamps
I31563Clamp
I31771
(A) 55-28
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
2643 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
35. INSTALL BLOWER ASSY
(a) Install the blower assy with the 2 screws and 2 nuts.
Torque: 1.5 NVm (15 kgfVcm, 12 in.Vlbf)
(b) Install the 6 clamps, connect the wire harness.
(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.
Torque: 20 NVm (203 kgfVcm, 14 ftVlbf) (Bolt A)

I31770
I3176910 Clamps
I315062 Clamps
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55-29
2644 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Install the 3 earth wires with the 3 nuts.
Torque: 8.4 NVm (85 kgfVcm, 73 in.Vlbf)
(c) Install the 10 clamps, connect the wire harness.
37. INSTALL STEERING COLUMN ASSY
(a) Install the steering column assy with the 3 bolts.
(b) Install the 2 clamps.

I31577
I31505
I31504
I31767
I317682 Clamps 55-30
- HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
2645 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Install the steering side connector block with the 2 nuts.
(d) Install the driver side junction block with the 3 nuts.
Torque: 8.4 NVm (85 kgfVcm, 73 in.Vlbf)
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.
(b) Install the 2 earth wires with the 2 bolts.
Torque: 8.4 NVm (85 kgfVcm, 73 in.Vlbf)
(c) Install the passenger side junction block with the nut and
2 clamps.
Torque: 8.4 NVm (85 kgfVcm, 73 in.Vlbf)