clutch LEXUS ES300 2005 Repair Manual

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
: Date
:
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.

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)

0103C-05
01-6- INTRODUCTIONTERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
6 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ASSYAssembly
AT FAutomatic Transaxle Fluid
B3U/D Brake
C2Reverse Clutch
C3U/D Clutch
FIPGFormed In Place Gasket
O/DOverdrive
SSMSpecial Service Materials
SSTSpecial Service Tools
U/DUnderdrive
w/With
w/oWithout
1stFirst
2ndSecond

0103D-09
- INTRODUCTIONTERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL01-7
7 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their Toyota equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )--ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal-
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric Pressure-
CACCharge Air CoolerInter cooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection-
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft positionCam Angle
CPPClutch Pedal Position-
CTOXContinuous Trap Oxidizer-
CTPClosed Throttle Potion-
DFIDirect Fuel Injection (Diesel)Direct Injection (DI)
DIDistributor Ignition-
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Communication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Code
DTMDiagnostic Test Mode-
ECLEngine Control Level-
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Control TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only
memoryElectrically Erasable Programmable Read Only memory
(EEPROM),
Erasable Programmable Read Only memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionDistributorless Ignition (DI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control-
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory-
FEPROMFlash Erasable Programmable Read Only Memory-
FFFlexible Fuel-
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)
HO2SHeated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdol Air ControlIdol Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module-
IFIIndirect Fuel InjectionIndirect Injection
IFSInertia Fuel-Shutoff-

01-8- INTRODUCTIONTERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
8 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U) ISC
Idle Speed Control-
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure-
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Light
MSTManifold Surface temperature-
MVZManifold Vacuum Zone-
NVRAMNon-V olatile Random Access Memory-
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn-Board DiagnosticOn-Board Diagnostic (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Converter (OC), CC0
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module-
PNPPark/Neutral Position-
PROMProgrammable Read Only Memory-
PSPPower Steering Pressure-
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module-
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger Bypass-
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter-
SRIService Reminder Indicator-
SRTSystem Readiness Test-
STScan Tool-
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter
TCMTransmission Control ModuleTransmission ECU (Electronic Control Unit)
TPThrottle PositionThrottle Position
TRTransmission Range-
TVVThermal Vacuum ValveBimetallic Vacuum Switching Valve (BVSV)
Thermostatic Vacuum Switching Valve (TVSV)
TWCThree-W ay Catalytic ConverterThree-W ay Catalytic (TWC)
CC
RO
TWC+OCThree-W ay + Oxidation Catalytic ConverterCCR + CCO
VA FVolume Air FlowAir Flow Meter
VRVoltage RegulatorVoltage Regulator
VSSVehicle Speed SensorVehicle Speed Sensor (Read Switch Type)
WOTWide Open ThrottleFull Throttle