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Home >> Lexus >> 2019 >> LS 500 Base, RWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Intake / Exhaust System - Service Information >> INTERCOOLER >> Installation [12/2017 - 10/2020] >> Procedure

Installation [12/2017 - 10/2020]: Procedure

  1. INSTALL INTAKE AIR SURGE TANK ASSEMBLY WITH INTERCOOLER 
    1. Install a new gasket to the intake air surge tank assembly with intercooler.

      HINT: 

      Check that the gasket is securely fitted into the groove on the installation area.

    2. Install the intake air surge tank assembly with intercooler with the 8 bolts in the order shown in the illustration.

      Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

      NOTE:

      Do not tighten the non-removable bolt.

      Fig 1: Intake Air Surge Tank Assembly With Intercooler Tightening Sequence
      GTY788548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Intake Air Surge Tank Assembly with Intercooler Installation Bolt
      Do not Tighten the Non-removable Bolt
    3. Connect the PCV hose to the intake air surge tank assembly with intercooler, and slide the clip to secure the hose.
    4. Install the 2 bolts.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  2. INSTALL NO. 2 INTERCOOLER SUPPORT BRACKET 
    1. Install the No. 2 intercooler support bracket to the intake air surge tank assembly with intercooler and cylinder head cover sub-assembly LH with the bolt and nut in the order shown in the illustration.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      Fig 2: No. 2 Intercooler Support Bracket Bolt And Nut Tightening Sequence
      GTY825368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL INTERCOOLER SUPPORT BRACKET 
    1. Install the intercooler support bracket to the intake air surge tank assembly with intercooler and cylinder head cover sub-assembly RH with the bolt and nut in the order shown in the illustration.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      Fig 3: Intercooler Support Bracket Bolt And Nut Tightening Sequence
      GTY784808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL NO. 2 SURGE TANK STAY 
    1. Install the No. 2 surge tank stay to the intake air surge tank assembly with intercooler and No. 2 timing chain cover assembly with the 2 bolts.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  5. INSTALL NO. 1 SURGE TANK STAY 
    1. Install the No. 1 surge tank stay to the intake air surge tank assembly with intercooler and No. 2 timing chain cover assembly with the 2 bolts.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  6. INSTALL E.F.I. VACUUM SENSOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  7. INSTALL NO. 3 TURBO PRESSURE SENSOR 

    Refer to PROCEDURE - Step 1

  8. INSTALL NO. 8 FUEL VAPOR FEED HOSE 
    1. Install the No. 8 fuel vapor feed hose to the intake air surge tank assembly with intercooler and fuel vapor feed pipe sub-assembly, and slide the clips to secure the hose.
  9. INSTALL NO. 9 FUEL VAPOR FEED HOSE 
    1. Install the No. 9 fuel vapor feed hose to the intake air surge tank assembly with intercooler and fuel vapor feed pipe sub-assembly, and slide the clips to secure the hose.
  10. INSTALL NO. 10 ENGINE WIRE 
    1. Connect the connectors, attach the clamps to connect the No. 10 engine wire from the intake air surge tank assembly with intercooler.
  11. INSTALL NO. 9 ENGINE WIRE 
    1. Connect the connectors, attach the clamps to connect the No. 9 engine wire from the intake air surge tank assembly with intercooler.
  12. INSTALL SURGE TANK COVER 
    1. Install the surge tank cover to the intake air surge tank assembly with intercooler.
  13. INSTALL NO. 1 WATER BY-PASS TUBE 
    NOTE:

    Do not bend the No. 1 water by-pass tube when removing it.

    1. Temporarily install the No. 1 water by-pass tube to the intake air surge tank assembly with intercooler with the 6 bolts.
    2. Tighten the 4 bolts.
      GTY795208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

    3. Tighten the bolt.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      GTY777017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the bolt.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      GTY795206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Bank 1 Side:
      1. Connect the No. 1 water by-pass pipe to the intake air surge tank assembly with intercooler and slide the retainer to secure it as shown in the illustration.
        NOTE:
        • Push in the retainer until a click sound is heard.
        • Pull on the No. 1 water by-pass pipe to confirm that the hose is securely connected.
        • If there is foreign matter on the union or the O-ring, clean it with water and finger scouring.
        GTY818888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Connect the No. 1 Water By-pass Pipe
        Insert the Retainer in the Direction of the Arrow Shown in the Illustration.
    6. Bank 2 Side:
      1. Connect the No. 1 water by-pass pipe to the intake air surge tank assembly with intercooler and slide the retainer to secure it as shown in the illustration.
        GTY778999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Connect the No. 1 Water By-pass Pipe
        Insert the Retainer in the Direction of the Arrow Shown in the Illustration.
        NOTE:
        • Push in the retainer until a click sound is heard.
        • Pull on the No. 1 water by-pass pipe to confirm that the hose is securely connected.
        • If there is foreign matter on the union or the O-ring, clean it with water and finger scouring.
    7. Connect the No. 1 turbo water hose and No. 2 turbo water hose to the No. 1 turbo water pipe sub-assembly, and slide the clips to secure the hose.
      NOTE:

      Be sure to correctly connect the No. 1 turbo water hose and No. 2 turbo water hose. Incorrect installation may damage the turbocharger sub-assembly.

      HINT: 

      Make sure the paint mark on the pipe side and the paint mark on the hose side are the same color.

      GTY789368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark (yellow)
      *b Paint Mark (white)
    8. Connect the No. 3 turbo water hose and No. 4 turbo water hose to the No. 2 turbo water pipe sub-assembly, and slide the clips to secure the hose.
      NOTE:

      Be sure to correctly connect the No. 3 turbo water hose and No. 4 turbo water hose. Incorrect installation may damage the turbocharger sub-assembly.

      HINT: 

      Make sure the paint mark on the pipe side and the paint mark on the hose side are the same color.

      GTY831809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark (yellow)
      *b Paint Mark (white)
    9. Connect the No. 1 water by-pass hose to the No. 1 water by-pass tube, and slide the clip to secure the hose.
    10. Connect the intercooler cooling water inlet hose and intercooler cooling water outlet hose, and slide the clips to secure the hose to the No. 1 water by-pass tube.
      GTY806726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Intercooler Outlet Pipe
      *b Intercooler Inlet Pipe
      *c Clip Installation Range 120°
      *d Front Side
      *f Vehicle Left Side
      *g Paint Mark (blue)
      *h Paint Mark (yellow)
      NOTE:

      Make sure the hose clips and paint marks is oriented as shown in the illustration.

  14. CONNECT HEATER WATER HOSE OUTLET 

    Refer to PROCEDURE - Step 120 [12/2017 - 09/2018] , or refer to PROCEDURE - Step 120 [09/2018 - 10/2020]

  15. CONNECT HEATER WATER HOSE INLET 

    Refer to PROCEDURE - Step 121 [12/2017 - 09/2018] , or refer to PROCEDURE - Step 121 [09/2018 - 10/2020]

  16. CONNECT ENGINE WIRE HARNESS 
    1. for Bank 1:
      1. Connect the connectors and attach the clamps to connect the engine wire harness.
        GTY827698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Install the 4 bolts.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

    2. Engine Front Side:
      1. Connect the connectors and attach the clamps to connect the engine wire harness.
        GTY777031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Install the 2 bolts.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      3. Connect the connectors and attach the clamps to connect the engine wire harness.
        GTY777034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Install the bolt.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

    3. for Bank 2:
      1. Connect the connectors to connect the engine wire harness.
        GTY777028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Install the 2 bolts.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      3. Connect the connectors and attach the clamps to connect the engine wire harness.
        GTY827699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Install the bolt.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  17. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 7

  18. INSTALL V-BANK COVER BRACKET 
    1. Install the No. 1 V-bank cover bracket and No. 2 V-bank cover bracket to the intake air surge tank assembly with intercooler with the 4 bolts.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  19. INSTALL FUEL VAPOR FEED PIPE 
    1. Install the fuel vapor feed pipe to the intake air surge tank assembly with intercooler with the 2 bolts.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  20. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to INSTALLATION [12/2017 - ]

  21. ADD COOLANT (for Intercooler) 

    Refer to PROCEDURE - Step 5

  22. INSPECT FOR COOLANT LEAK (for Intercooler) 

    See step  1

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