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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 [12/2017 - 10/2020] >> Procedure

Removal [12/2017 - 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.
      GTY777040Courtesy 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.
      GTY777035Courtesy 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.
        GTY795204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disconnect the connectors and detach the clamp.
      3. Remove the 2 bolts.
        GTY777028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Disconnect the connectors.
    2. Engine Front Side:
      1. Remove the 2 bolts.
        GTY777031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disconnect the connectors and detach the clamps.
      3. Remove the bolt.
        GTY807087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Disconnect the connectors and detach the clamps.
    3. for Bank 1:
      1. Remove the 4 bolts.
        GTY827698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disconnect the connectors and detach the clamps.
  7. DISCONNECT HEATER WATER HOSE INLET 

    Refer to PROCEDURE - Step 50 [12/2017 - 09/2018] , or refer to PROCEDURE - Step 50 [09/2018 - 10/2020]

  8. DISCONNECT HEATER WATER HOSE OUTLET 

    Refer to PROCEDURE - Step 51 [12/2017 - 09/2018] , or refer to PROCEDURE - Step 51 [09/2018 - 10/2020]

  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.
      GTY777024Courtesy 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.
      GTY777026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. 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
    5. 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.
        GTY791901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Move the Retainer Upwards
        Disconnect the No. 1 Water By-pass Pipe
    6. 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.
        GTY785753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Move the Retainer Upwards
        Disconnect the No. 1 Water By-pass Pipe
    7. 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
    8. 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 SURGE TANK COVER 
    1. Remove the surge tank cover from the intake air surge tank assembly with intercooler.
      GTY777013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. 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.
      GTY777014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. 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.
      GTY827694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. 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.
      GTY777004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. 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.
      GTY777003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE NO. 3 TURBO PRESSURE SENSOR 

    Refer to PROCEDURE - Step 6

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

    Refer to PROCEDURE - Step 5

  17. 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.
      GTY777000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. 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.
      GTY777005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE INTERCOOLER SUPPORT BRACKET 
    1. Remove the bolt and nut in several steps and in the sequence shown in the illustration.
      Fig 1: Intercooler Support Bracket Bolt And Nut Tightening Sequence
      GTY784808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE NO. 2 INTERCOOLER SUPPORT BRACKET 
    1. Remove the bolt and nut in several steps and in the sequence shown in the illustration.
      Fig 2: No. 2 Intercooler Support Bracket Bolt And Nut Tightening Sequence
      GTY825368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE INTAKE AIR SURGE TANK ASSEMBLY WITH INTERCOOLER 
    1. Remove the 2 bolts.
      GTY777002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the PCV hose from the intake air surge tank assembly with intercooler.
      GTY827691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 8 bolts and intake air surge tank assembly with intercooler.

      HINT: 

      Do not loosen the non-removable bolt shown in the illustration.

      GTY830217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Intake Air Surge Tank Assembly with Intercooler Installation Bolt
      Do not Tighten the Non-removable Bolt
    4. Remove the gasket from the intake air surge tank assembly with intercooler.
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