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

Removal [10/2020 - ]: Procedure

  1. DRAIN COOLANT (for Intercooler) 

    Refer to PROCEDURE - Step 4

  2. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to REMOVAL [12/2017 - ]

  3. DISCONNECT FUEL VAPOR FEED PIPE 
    1. Remove the 2 bolts and disconnect the fuel vapor feed pipe from the intake air surge tank assembly with intercooler.
      GTY964553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE V-BANK COVER BRACKET 
    1. Remove the 4 bolts, No. 1 V-bank cover bracket and No. 2 V-bank cover bracket from the intake air surge tank assembly with intercooler.
      GTY964759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 12

  6. DISCONNECT ENGINE WIRE HARNESS 
    1. for Bank 2:
      1. Remove the bolt.
        GTY965552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disconnect the connectors and detach the clamp.
      3. Remove the 2 bolts.
        GTY964753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Disconnect the connectors and detach the clamp.
    2. Engine Front Side:
      1. Remove the 2 bolts.
        GTY964552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disconnect the connectors and detach the clamps.
      3. Remove the bolt.
        GTY964658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Disconnect the connectors and detach the clamps.
    3. for Bank 1:
      1. Remove the 4 bolts.
        GTY964659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disconnect the connectors and detach the clamps.
  7. DISCONNECT INLET HEATER WATER HOSE 

    Refer to PROCEDURE - Step 50 [10/2020 - 10/2022] , or refer to PROCEDURE - Step 50 [10/2022 - 10/2023] , or refer to PROCEDURE - Step 50 [10/2023 - ]

  8. DISCONNECT OUTLET HEATER WATER HOSE 

    Refer to PROCEDURE - Step 51 [10/2020 - 10/2022] , or refer to PROCEDURE - Step 51 [10/2022 - 10/2023] , or refer to PROCEDURE - Step 51 [10/2023 - ]

  9. REMOVE NO. 1 WATER BY-PASS TUBE 
    NOTE:

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

    1. Remove the 5 bolts.
      GTY964532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clips and disconnect the intercooler cooling water inlet hose and intercooler cooling water outlet hose from the No. 1 water by-pass tube.
      GTY777025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Slide the clip and disconnect the No. 1 water by-pass hose from the No. 1 water by-pass tube.
      GTY964660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Slide the clips and disconnect the No. 3 turbo water hose and No. 4 turbo water hose from the No. 2 turbo water pipe sub-assembly.
      GTY777015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Slide the clips and disconnect the No. 1 turbo water hose and No. 2 turbo water hose from the turbo water pipe sub-assembly.
      GTY777016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. for Bank 1:
      1. Move the retainer and disconnect the No. 1 water by-pass pipe from the intake air surge tank assembly with intercooler as shown in the illustration.
        GTY964639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Move the Retainer Upwards
        Disconnect the No. 1 Water By-pass Pipe
    7. for Bank 2:
      1. Move the retainer and disconnect the No. 1 water by-pass pipe from the intake air surge tank assembly with intercooler as shown in the illustration.
        GTY964929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Move the Retainer Upwards
        Disconnect the No. 1 Water By-pass Pipe
    8. Remove the bolt and disconnect the No. 1 water by-pass tube clamp from the No. 2 water outlet pipe.
      GTY807124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the bolt and No. 1 water by-pass tube from the intake air surge tank assembly with intercooler.
      GTY777017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE NO. 9 ENGINE WIRE 
    1. Disconnect the connectors, detach the clamps and disconnect the No. 9 engine wire from the intake air surge tank assembly with intercooler.
      GTY964663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE NO. 10 ENGINE WIRE 
    1. Disconnect the connectors, detach the clamps and disconnect the No. 10 engine wire from the intake air surge tank assembly with intercooler.
      GTY964664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 9 FUEL VAPOR FEED HOSE 
    1. Slide the clips and remove the No. 9 fuel vapor feed hose from the intake air surge tank assembly with intercooler and fuel vapor feed pipe sub-assembly.
      GTY964533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE NO. 8 FUEL VAPOR FEED HOSE 
    1. Slide the clips and remove the No. 8 fuel vapor feed hose from the intake air surge tank assembly with intercooler and fuel vapor feed pipe sub-assembly.
      GTY964761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE NO. 3 TURBO PRESSURE SENSOR 

    Refer to PROCEDURE - Step 6

  15. REMOVE E.F.I. VACUUM SENSOR ASSEMBLY 

    Refer to PROCEDURE - Step 5

  16. REMOVE NO. 1 SURGE TANK STAY 
    1. Remove the 2 bolts and No. 1 surge tank stay from the No. 2 timing chain cover assembly and intake air surge tank assembly with intercooler.
      GTY964571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE NO. 2 SURGE TANK STAY 
    1. Remove the 2 bolts and No. 2 surge tank stay from the No. 2 timing chain cover assembly and intake air surge tank assembly with intercooler.
      GTY964844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE INTERCOOLER SUPPORT BRACKET 
    1. Remove the bolt, nut and intercooler support bracket from the cylinder head cover sub-assembly RH and intake air surge tank assembly with intercooler.
      GTY777001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE NO. 2 INTERCOOLER SUPPORT BRACKET 
    1. Remove the bolt, nut and No. 2 intercooler support bracket from the cylinder head cover sub-assembly LH and intake air surge tank assembly with intercooler.
      GTY777006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE INTAKE AIR SURGE TANK ASSEMBLY WITH INTERCOOLER 
    1. Remove the 2 bolts.
      GTY964845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. GTY827691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Slide the clip and disconnect the No. 1 PCV hose from the intake air surge tank assembly with intercooler.

    3. Remove the 8 bolts and intake air surge tank assembly with intercooler.
      GTY964846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the gasket from the intake air surge tank assembly with intercooler.
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