2003 Lexus ES300 Service & Repair Manual

550BQ-01 AC2810 AC2811 N11084 Wrong Okay HI LO HI LO - HEATER & AIR CONDITIONER AIR CONDITIONING SYSTEM 55-1 2616 Author: Date: 2005 LEXUS ES330 REPAIR MANUAL (RM1124U) AIR CONDITIONING SYSTEM PRECAUTION 1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME 2. ALWAYS WEAR EYE PROTECTION 3. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin. (a) Wash the area with lots of cool water. CAUTION: Do not rub your eyes or skin. (b) Apply clean petroleum jelly to the skin. (c) Go immediately to a physician or hospital for professional treatment. 4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME 5. BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT 6. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM If there is not enough refrigerant in the refrigerant system oil lu- brication will be insufficient and compressor burnout may occur, so take care to avoid this, necessary care should be taken. 7. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING If the high pressure valves opened, refrigerant flows in the re- verse direction and could cause the charging cylinder to rup- ture, so open and close the only low pressure valve. 8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating etc.

550D4-02 I31521 Sight Glass 55-2 - HEATER & AIR CONDITIONER REFRIGERANT 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: z Running engine at 1,500 rpm z Blower speed control switch at ”HI” z A/C switch ON z Temperature control dial at ”MAX. COOL” z Fully open the doors Item Symptom Amount of refrigerant Corrective Actions 1 Bubbles present Insufficient* (1) Check for gas leakage and repair if necessary (2) Add refrigerant until bubbles disappear 2 No bubbles present None, insufficient or too much Refer 3 and 4 3 No temperature difference between compressor inlet and outlet Empty or nearly empty (1) Check for gas leakage with gas leak de- tector and repair if necessary (2) Add refrigerant until bubbles disappear 4 Considerable temperature difference between compressor inlet and outlet. Correct or too much Refer to 5 and 6 5 Immediately after air conditioning is turned off, refrigerant clear Too 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 CONDITIONER REFRIGERANT 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: z Temperature at the air inlet with the switch set at RECIRC is 30 - 35 °C (86 - 95 °F) z Engine running at 1,500 rpm z Blower speed control switch at ”HI” position z Temperature control dial at ”COOL” position z A/C switch ON z 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. Symptom Probable cause Diagnosis Remedy 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. z Drier in oversaturected state z Moisture in refrigerating system freezes at expansion valve orifice and blocks circulation of refrigerant (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 CONDITIONER REFRIGERANT 2619 Author: Date: 2005 LEXUS ES330 REPAIR MANUAL (RM1124U) (3) Insufficient cooling Symptom Probable cause Diagnosis Corrective Actions z Pressure low on both low and high pressure sides z Bubbles seen thought sight glass continuously z Insufficient cooling performance Gas leakage in refrigeration system z Insufficient refrigerant z Refrigerant leaking (1) Check for gas leakage and repair 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 Symptom Probable cause Diagnosis Corrective Action z Pressure low on both low and high pressure sides z Frost on pipe from condenser to unit Refrigerant flow obstructed by dirt in receiver Receiver clogged Replace condenser

I22120 Condition: Cooling system does not function. (Sometimes it way function) I22121 Condition: Cooling system does not function effectively. - HEATER & AIR CONDITIONER REFRIGERANT 55-5 2620 Author: Date: 2005 LEXUS ES330 REPAIR MANUAL (RM1124U) (5) Refrigerant does not circulate Symptom Probable cause Diagnosis Corrective Actions z Vacuum indicated on low pressure side, very low pressure indicated on high pressure side z Frost or dew seen on piping be- fore and after receiver/ drier or expansion valve z Refrigerant flow obstructed by moisture or dirt in refrigerating system z 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 proper amount of new refrigerant. (5) For gas leakage from expansion valve, replace expansion valve (6) Refrigerant overcharged or insufficient cooling of condenser Symptom Probable cause Diagnosis Remedy z Pressure too high on both low and high pressure sides z No sir bubbles seen through the sight glass even when the engine rpm is lowered z Unable to develop sufficient performance due to excessive use of refrigerating system z Insufficient cooling of condenser z Excessive refrigerant in cycle→too much refrigerant sup- plied z 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 refrigerant

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2003 Lexus ES300 Service & Repair Manual

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