gas LEXUS ES300 2005 Repair Manual
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
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 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 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 41 of 969
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))
Page 43 of 969
550DG-02
- HEATER & AIR CONDITIONERCOOLER CONDENSER ASSY
55-43
2658 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
COOLER CONDENSER ASSY
ON-VEHICLE INSPECTION
1. INSPECT COOLER CONDENSER ASSY
(a) If a fin of the cooler condenser assy is dirty, clean it with water and dry it with compressor air.
NOTICE:
Do not damage the fin of the condenser assy.
(b) If a fin of the condenser assy is bent, make it straight using a screwdriver or pliers.
2. INSPECT CONDENSER FOR LEAKAGE OF REFRIGERANT
(a) Using a halogen leak detector, check pipe joints for gas leakage.
(b) If gas leakage is detected in a joint, check the torque of the joint.
Page 52 of 969
0103B-07
Z11554
Seal Lock Adhesive 01-4
- INTRODUCTIONREPAIR INSTRUCTION FOR AUTOMATIC
TRANSAXLE REPAIR MANUAL
4 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
REPAIR INSTRUCTION FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL
PRECAUTION
1. BASIC REPAIR HINT
(a) PRECOATED PARTS
(1) Precoated parts are bolts, nuts, etc. that are coated
with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(3) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.
NOTICE:
Do the torque checking with the lower limit value of the torque tolerance.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave
it for a specified time until it hardens.
(b) GASKETS
When necessary, use a sealer on gaskets to prevent leaks.
(c) BOLTS, NUTS AND SCREWS
Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
Page 54 of 969
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
Page 55 of 969
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-
Page 73 of 969
4010I-01
C86320
N´m (kgf´cm, ft´lbf): Specified torque
Non-reusable partElbow
27 (276, 20)
Drain Plug Drain Plug Gasket Automatic Transmission
Case PlugO-Ring Automatic Transmission
Case Plug Speed Sensor
Automatic Transmission
Case Plug
47 (479, 34)
Speed Sensor
7.4 (75, 65 in.Vlbf)
O-Ring O-Ring
O-Ring
O-Ring
O-Ring
7.4 (75, 65 in.Vlbf)
7.4 (75, 65 in.Vlbf)
11.3 (158, 8)
11.3 (158, 8)
5.4 (55, 48 in.Vlbf)
U151E:
Transmission Wire
Union
25 (255, 18)
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)40-1
25 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
AUTOMATIC TRANSMISSION / TRANSAXLE (U151E/U151F)
COMPONENTS