Lexus Car ES, IS, LS 1998-06

Removal & Installation

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Click image to see an enlarged view

Fig. Exploded view of A/C compressor assembly.-ES 300 and ES 330

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de-energizes.
  4.  
  5. Discharge the A/C system.
  6.  
  7. Remove the accessory drive belt.
  8.  
  9. Remove the alternator.
  10.  
  11. Remove the nut and disconnect the cooler refrigerant discharge hose No. 1.
  12.  
  13. Remove the O-ring from the cooler refrigerant discharge hose No. 1.
    NOTE
    Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  14.  
  15. Remove the nut and disconnect the cooler refrigerant suction hose No. 1.
  16.  
  17. Remove the O-ring from the cooler refrigerant suction hose No. 1.
    NOTE
    Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  18.  
  19. Remove the compressor assembly as follows:


    1. Disconnect the connector and clamp.
    2.  
    3. Remove the 2 bolts, nut and cooler compressor bracket.
    4.  
    5. Remove the 3 bolts and the compressor assembly.
    6.  

  20.  
  21. Remove the screw, ground wire and cooler compressor bracket.
  22.  

To install:

  1. Install the ground wire and cooler compressor bracket with the screw.
  2.  
  3. When replacing the compressor and magnetic clutch with new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor and magnetic clutch before installation.
    WARNING
    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, preventing 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.



    Standard: (Oil capacity inside new compressor and magnetic clutch: 4.1 + 0.51 fl.oz. (120 + 15cc) ) - (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed when replacing)
     
    When checking the compressor oil level, observe the precautions on the cooler removal/installation.
     

  4.  
  5. Install and temporarily tighten the compressor and magnetic clutch with the 3 bolts.

    Click image to see an enlarged view

    Fig. Fully tighten compressor bolts (A) and (B).-ES 300 and ES 330



    Click image to see an enlarged view

    Fig. Compressor bracket-to-compressor bolts (C and E) and nut (D).-ES 300 and ES 330



    Click image to see an enlarged view

    Fig. Bolt (F) location on the compressor.-ES 300 and ES 330

  6.  
  7. Fully tighten the compressor bolts (A) and (B) to 18 ft. lbs. (25 Nm).
  8.  
  9. Install the compressor bracket with the 2 bolts (C and E) and nut (D). Tighten bolt (C) and the nut (D) to 18 ft. lbs. (25 Nm). Tighten bolt (E) to 13 ft. lbs. (18 Nm).
  10.  
  11. Tighten the compressor and magnetic clutch with the bolt (F). Tighten bolt (F) to 18 ft. lbs. (25 Nm).
  12.  
  13. Connect the electrical connector.
  14.  
  15. Install cooler refrigerant suction hose No. 1 as follows:


    1. Remove the attached vinyl tape from the hose.
    2.  
    3. Sufficiently apply compressor oil to the new O-ring and fit surface of the compressor and magnetic clutch. Use compressor oil ND-OIL 8 or equivalent.
    4.  
    5. Install a O-ring to the cooler refrigerant suction hose No. 1.
    6.  
    7. Install the cooler refrigerant suction hose No. 1 to the compressor and magnetic clutch with the nut and tighten to 87 inch lbs. (10 Nm).
    8.  

  16.  
  17. Install cooler refrigerant discharge hose No. 1 as follows:


    1. Remove the attached vinyl tape from the hose.
    2.  
    3. Sufficiently apply compressor oil to the new O-ring and fit surface of the compressor and magnetic clutch. Use compressor oil ND-OIL 8 or equivalent.
    4.  
    5. Install a O-ring to the cooler refrigerant discharge hose No. 1.
    6.  
    7. Install the cooler refrigerant discharge hose No. 1 to the compressor and magnetic clutch with the nut and tighten to 87 inch lbs. (10 Nm).
    8.  

  18.  
  19. Install the alternator.
  20.  
  21. Install the accessory drive belt.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Charge the A/C system.
  26.  
  27. Start the engine and allow enough time to warm up.
  28.  
  29. Inspect the A/C system for refrigerant leakage.
  30.  



Click image to see an enlarged view

Fig. Exploded view of A/C compressor assembly.-IS 300

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Run the engine at idle speed with the A/C on for approximately 10 minutes.
  4.  
  5. Stop the engine.
  6.  
  7. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de-energizes.
  8.  
  9. Discharge the A/C system.
  10.  
  11. Remove the accessory drive belt.
  12.  
  13. Remove the 2 nuts and disconnect the both hoses from the compressor.
    NOTE
    Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  14.  
  15. Remove the power steering pump, leaving the feed and return hoses still connected.
  16.  
  17. Remove the compressor assembly as follows:


    1. Remove the bolt and power steering pump bracket.
    2.  
    3. Remove the 3 bolts and compressor bracket.
    4.  
    5. Disconnect the electrical connector.
    6.  
    7. Remove the nut and 2 bolts.
    8.  
    9. Using a torx socket (E10), remove the stud bolt and compressor.
    10.  

  18.  

To install:

Click image to see an enlarged view

Fig. Location of compressor mounting bolts A and B-IS 300

  1. Install the compressor assembly as follows:


    1. Install the compressor with the stud bolt and tighten to 19 ft. lbs. (26 Nm).
    2.  
    3. Install the 2 bolts and nut and tighten them to 38 ft. lbs. (52 Nm).
    4.  
    5. Connect the electrical connector.
    6.  
    7. Install the compressor bracket with the 3 bolts. Torque bolt A to 29 ft. lbs. (39 Nm) and bolt B to 38 ft. lbs. (52 Nm).
    8.  
    9. Install the power steering pump bracket with the bolt and tighten to 38 ft. lbs. (52 Nm).
    10.  

  2.  
  3. Install the power steering pump.
  4.  
  5. Lubricate 2 new O-rings with compressor oil and install them to the discharge and suction hoses.
  6.  
  7. Connect both hoses with 2 nuts and tighten to 7 ft. lbs. (10 Nm).
    NOTE
    Hose should be connected immediately after the caps have been removed.

  8.  
  9. Install the accessory drive belt and inspect the belt tension.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Evacuate and charge the A/C system.
  14.  
  15. Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints.
  16.  
  17. Inspect the A/C operation.
  18.  



Click image to see an enlarged view

Fig. Exploded view of A/C compressor assembly.-IS 250 w/AWD

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de-energizes.
  4.  
  5. Remove the cool air intake duct seal.
  6.  
  7. Remove the V-bank cover.
  8.  
  9. Remove the No. 1 inlet air cleaner.
  10.  
  11. Discharge the A/C system.
  12.  
  13. Remove the under engine cover.
  14.  
  15. Remove the accessory drive belt.
  16.  
  17. Remove the bolt, nut, and oil filter bracket.

    Click image to see an enlarged view

    Fig. Oil filter bracket sub-assembly-IS 250 w/AWD

  18.  
  19. Remove the oil filter bracket sub-assembly as follows:


    1. Disconnect the electrical connector and 2 clamps, and separate the wire harness.
    2.  
    3. Remove the 2 nuts, bolts, and oil filter bracket sub-assembly.
      NOTE
      Place a container under the connection because engine oil will leak out when separating the oil filter bracket.

    4.  

  20.  
  21. Remove the bolt and disconnect the No. 1 cooler refrigerant suction hose from the compressor.
  22.  
  23. Remove the O-ring from the cooler refrigerant suction hose.
    NOTE
    Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  24.  
  25. Remove the bolt and disconnect the discharge hose from the compressor.
  26.  
  27. Remove the O-ring from the discharge hose.
    NOTE
    Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  28.  
  29. Remove the compressor assembly as follows:


    1. Disconnect the magnetic clutch connector.
    2.  
    3. Remove the 2 bolts and nut.
    4.  
    5. Using a "Torx" socket wrench (E8), remove the stud bolt and the compressor and magnetic clutch assembly.
    6.  

  30.  

To install:

  1. Using an E8 "torx" socket, install the compressor with the stud bolt and tighten to 7 ft. lbs. (10 Nm).
  2.  
  3. Temporarily tighten the cooler compressor with magnetic clutch assembly with the 2 bolts and nut.
  4.  
  5. Install discharge hose as follows:


    1. Remove the attached vinyl tape from the hose.
    2.  
    3. Sufficiently apply compressor oil to the new O-ring and fit surface of the compressor and magnetic clutch. Use compressor oil ND-OIL 8 or equivalent.
    4.  
    5. Install a O-ring to the discharge hose.
    6.  
    7. Install the discharge hose to the compressor and magnetic clutch with the bolt and tighten to 87 inch lbs. (10 Nm).
    8.  

  6.  
  7. Install the No. 1 cooler refrigerant suction hose as follows:


    1. Remove the attached vinyl tape from the hose.
    2.  
    3. Sufficiently apply compressor oil to the new O-ring and fit surface of the compressor and magnetic clutch. Use compressor oil ND-OIL 8 or equivalent.
    4.  
    5. Install a O-ring to the No. 1 cooler refrigerant suction hose.
    6.  
    7. Install the No. 1 cooler refrigerant suction hose to the compressor and magnetic clutch with the bolt and tighten to 87 inch lbs. (10 Nm).
    8.  

  8.  
  9. Install the oil filter bracket sub-assembly as follows:


    1. Install a new oil filter bracket gasket and the oil filter bracket sub-assembly with the 2 nuts and bolt and tighten to 15 ft. lbs. (21 Nm).
    2.  
    3. Connect the electrical connector and install the wire harness with the 2 clamps.
    4.  

  10.  
  11. Install the oil filter bracket with the bolt and nut. Tighten the bolt and nut to 18 ft. lbs. (25 Nm).
    NOTE
    Tighten the bolts in the order shown in the illustration to install the compressor.



    Click image to see an enlarged view

    Fig. Bolt tightening order of A/C compressor assembly.-IS 250 w/AWD

  12.  
  13. Install the compressor and magnetic clutch assembly with the bolts and nut. Tighten the bolts and nut to 18 ft. lbs. (25 Nm).
    NOTE
    Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch assembly.

  14.  
  15. Install the accessory drive belt.
  16.  
  17. Install the under engine cover.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Charge the A/C system.
  22.  
  23. Start the engine and allow enough time to warm up.
  24.  
  25. Inspect the A/C system for refrigerant leakage.
  26.  
  27. Install the No. 1 inlet air cleaner.
  28.  
  29. Install the V-bank cover.
  30.  
  31. Install the cool air intake duct seal.
  32.  



Click image to see an enlarged view

Fig. Exploded view of A/C compressor assembly.-LS 400

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Run the engine at idle speed with the A/C on for approximately 10 minutes.
  4.  
  5. Stop the engine.
  6.  
  7. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de-energizes.
  8.  
  9. Discharge the A/C system.
  10.  
  11. Remove the 2 nuts and disconnect the both hoses from the compressor.
    NOTE
    Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  12.  
  13. Remove the accessory drive belt.
  14.  
  15. Remove the engine under cover.
  16.  
  17. Remove the compressor assembly as follows:


    1. Disconnect the electrical connector.
    2.  
    3. Remove the bolt and disconnect the ground wire.
    4.  
    5. Remove the nut, the 3 bolts, compressor No.1 Stay and the compressor.
    6.  

  18.  

To install:

  1. Install the compressor assembly as follows:


    1. Install the compressor with the stay and 3 bolts. Tighten the bolts to 36 ft. lbs. (49 Nm), and the nut to 22 ft. lbs. (29 Nm).
    2.  
    3. Connect the earth wire harness with the bolts.
    4.  
    5. Connect the electrical connector.
    6.  

  2.  
  3. Install the engine under cover.
  4.  
  5. Lubricate the 2 new O-rings with compressor oil and install them to the discharge and suction hoses.
  6.  
  7. Connect both hoses with 2 nuts and tighten to 7 ft. lbs. (10 Nm).
    NOTE
    Hose should be connected immediately after the caps have been removed.

  8.  
  9. Install the accessory drive belt and inspect the belt tension.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Evacuate and charge the A/C system.
  14.  
  15. Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints.
  16.  
  17. Inspect the A/C operation.
  18.  



Click image to see an enlarged view

Fig. Exploded view of A/C compressor assembly.-LS 430

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de-energizes.
  4.  
  5. Discharge the A/C system.
  6.  
  7. Remove the air cleaner inlet No. 1.
  8.  
  9. Remove the accessory drive belt.
  10.  
  11. Remove the engine under cover No. 1.
  12.  
  13. Remove the nut and disconnect the cooler refrigerant discharge hose No. 1.
  14.  
  15. Remove the O-ring from the cooler refrigerant discharge hose No. 1.
    NOTE
    Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  16.  
  17. Remove the bolt and disconnect the cooler refrigerant suction hose No. 1.
  18.  
  19. Remove the O-ring from the cooler refrigerant suction hose No. 1.
    NOTE
    Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  20.  
  21. Remove the compressor assembly as follows:


    1. Remove the bolt, nut and compressor mounting bracket No.1.
    2.  
    3. Disconnect the connector and clamp.
    4.  
    5. Remove the 3 bolts and the compressor assembly.
    6.  

  22.  

To install:

  1. When replacing the compressor and magnetic clutch with new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor and magnetic clutch before installation.
    WARNING
    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, preventing 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-OIL 8 or equivalent for compressor oil.



    Standard: (Oil capacity inside new compressor: 4.4 + 0.5 fl.oz. (130 + 15cc) ) - (Remaining oil amount in the removed compressor) = (Oil amount to be removed when replacing)
     
    When checking the compressor oil level, observe the precautions on the air conditioning radiator assembly removal/installation.
     

  2.  
  3. Install and temporarily tighten the compressor and magnetic clutch assembly with the 2 bolts and connect the electrical connector.
  4.  
  5. Install the compressor mounting bracket No. 1 with the bolt and nut. Tighten bolt to 36 ft. lbs. (49 Nm), and tighten the nut to 22 ft. lbs. (30 Nm).
  6.  
  7. Fully tighten the 2 compressor assembly bolts to 36 ft. lbs. (49 Nm).
  8.  
  9. Install cooler refrigerant suction hose No. 1 as follows:


    1. Remove the attached vinyl tape from the hose.
    2.  
    3. Sufficiently apply compressor oil to the new O-ring and fit surface of the compressor and magnetic clutch. Use compressor oil ND-OIL 8 or equivalent.
    4.  
    5. Install a O-ring to the cooler refrigerant suction hose No. 1.
    6.  
    7. Install the cooler refrigerant suction hose No. 1 to the compressor and magnetic clutch with the bolt and tighten to 87 inch lbs. (10 Nm).
    8.  

  10.  
  11. Install cooler refrigerant discharge hose No. 1 as follows:


    1. Remove the attached vinyl tape from the hose.
    2.  
    3. Sufficiently apply compressor oil to the new O-ring and fit surface of the compressor and magnetic clutch. Use compressor oil ND-OIL 8 or equivalent.
    4.  
    5. Install a O-ring to the cooler refrigerant discharge hose No. 1.
    6.  
    7. Install the cooler refrigerant discharge hose No. 1 to the compressor and magnetic clutch with the nut and tighten to 87 inch lbs. (10 Nm).
    8.  

  12.  
  13. Install the accessory drive belt.
  14.  
  15. Install the air cleaner inlet No. 1.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Charge the A/C system.
  20.  
  21. Start the engine and allow enough time to warm up.
  22.  
  23. Inspect the A/C system for refrigerant leakage.
  24.  

Is 250 W/2wd And Is 350





Click image to see an enlarged view

Fig. Exploded view of A/C compressor assembly.-IS 250 w/2WD and IS 350

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de-energizes.
  4.  
  5. Remove the cool air intake duct seal.
  6.  
  7. Remove the V-bank cover.
  8.  
  9. Remove the No. 1 inlet air cleaner.
  10.  
  11. Discharge the A/C system.
  12.  
  13. Remove the accessory drive belt.
  14.  
  15. Remove the under engine cover.
  16.  
  17. Remove the left rear engine under cover.
  18.  
  19. Remove the bolt and disconnect the No. 1 cooler refrigerant suction hose from the compressor.
  20.  
  21. Remove the O-ring from the cooler refrigerant suction hose.
    NOTE
    Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  22.  
  23. Remove the bolt and disconnect the discharge hose from the compressor.
  24.  
  25. Remove the O-ring from the discharge hose.
    NOTE
    Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  26.  
  27. Remove the compressor assembly as follows:


    1. Disconnect the magnetic clutch connector.
    2.  
    3. Remove the 3 bolts and nut.
    4.  
    5. Remove the compressor assembly.
    6.  

  28.  

To install:

  1. Install the compressor assembly as follows:


    1. Temporarily install the compressor and magnetic clutch assembly onto the stud bolt.
    2.  
    3. Install the compressor and magnetic clutch assembly with the 3 bolts and nut. Tighten the 3 bolts and nut to 18 ft. lbs. (25 Nm).
      NOTE
      Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.



      Click image to see an enlarged view

      Fig. Bolt tightening order of A/C compressor assembly.-IS 250 w/2WD and IS 350

    4.  

  2.  
  3. Install discharge hose as follows:


    1. Remove the attached vinyl tape from the hose.
    2.  
    3. Sufficiently apply compressor oil to the new O-ring and fit surface of the compressor and magnetic clutch. Use compressor oil ND-OIL 8 or equivalent.
    4.  
    5. Install a O-ring to the discharge hose.
    6.  
    7. Install the discharge hose to the compressor and magnetic clutch with the bolt and tighten to 87 inch lbs. (10 Nm).
    8.  

  4.  
  5. Install the No. 1 cooler refrigerant suction hose as follows:


    1. Remove the attached vinyl tape from the hose.
    2.  
    3. Sufficiently apply compressor oil to the new O-ring and fit surface of the compressor and magnetic clutch. Use compressor oil ND-OIL 8 or equivalent.
    4.  
    5. Install a O-ring to the No. 1 cooler refrigerant suction hose.
    6.  
    7. Install the No. 1 cooler refrigerant suction hose to the compressor and magnetic clutch with the bolt and tighten to 87 inch lbs. (10 Nm).
    8.  

  6.  
  7. Install the accessory drive belt.
  8.  
  9. Install the left rear engine under cover.
  10.  
  11. Install the under engine cover.
  12.  
  13. Install the No. 1 inlet air cleaner.
  14.  
  15. Install the V-bank cover.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Charge the A/C system.
  20.  
  21. Start the engine and allow enough time to warm up.
  22.  
  23. Inspect the A/C system for refrigerant leakage.
  24.  
  25. Install the cool air intake duct seal.
  26.  

 
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