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Home >> Lexus >> 2024 >> RX 500h >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Intake / Exhaust System - Service Information >> INTERCOOLER (for Gasoline Model) >> Installation [10/2022 - ] >> Procedure

Installation [10/2022 - ]: Procedure

  1. INSTALL INTERCOOLER ASSEMBLY 
    1. GTY1080557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install a new gasket to the intake manifold as shown in the illustration.
      2. Install a new gasket to the intercooler assembly as shown in the illustration
      3. Using an 8 mm socket wrench, install the No. 2 turbo pressure sensor to the intake manifold with the bolt.

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

      4. Install the intercooler assembly to the intake manifold with the 4 nuts and bolts.

        for Nut 

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

        for Bolt 

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

  2. INSTALL NO. 6 INTERCOOLER COOLING WATER HOSE 
    1. GTY1129842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 30° (Tabs of Clip Installation Area)
      *c Paint Mark - -
      1. Connect the No. 6 Intercooler cooling water hose to the No. 1 intercooler cooling water pipe and slide the clip to secure it.
        NOTE:
        • Make sure to slide the No. 6 Intercooler cooling water hose until it contacts the hose stopper of the No. 1 intercooler cooling water pipe.
        • Make sure that the tabs of the clip are within the area shown in the illustration.

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

    2. GTY1130444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 7 INTERCOOLER COOLING WATER HOSE 
    1. GTY1133297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 30° (Tabs of Clip Installation Area)
      *c Paint Mark *d Rear Side of Vehicle
      *e Upper Side of Vehicle - -
      1. Connect the No. 7 intercooler cooling water hose to the No. 2 intercooler cooling water pipe and slide the clip to secure it.
        NOTE:
        • Make sure to slide the No. 7 intercooler cooling water hose until it contacts the hose stopper of the No. 2 intercooler cooling water pipe.
        • Make sure that the tabs of the clip are within the area shown in the illustration.

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

    2. GTY1130440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL INTAKE MANIFOLD WITH INTERCOOLER ASSEMBLY 
    1. GTY1077797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily place the intake manifold assembly and fuel delivery guard in this order.
      2. Tighten the 7 bolts and 2 nuts in the order shown in the illustration.

        for Bolt (*a) 

        Torque: 24 N.m (245 kgf/cm, 18 ft.lbf) 

        for Bolt (*b) 

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

        for Nut (*c) 

        Torque: 24 N.m (245 kgf/cm, 18 ft.lbf) 

  5. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    Refer to PROCEDURE - Step 44
  6. CONNECT NO. 5 WATER BY-PASS HOSE (Type B) 
  7. CONNECT NO. 4 WATER BY-PASS HOSE 
    1. GTY1130844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 45° (Tabs of Clip Installation Area)
      *c Paint Mark *d Upper Side of Vehicle
      1. Connect the No. 4 water by-pass hose so that the paint mark is in the position shown in the illustration.
      2. Connect the No. 4 water by-pass hose to the water control valve and slide the clip to secure it.
        NOTE:
        • Make sure to slide the No. 4 water by-pass hose assembly until it contacts the hose stopper of the water control valve.
        • Make sure that the tabs of the clip are within the area shown in the illustration.
  8. CONNECT NO. 2 INTERCOOLER COOLING WATER HOSE 
    1. GTY1079035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 60°
      *c 70° *d Paint Mark
      *e Upper Side of Vehicle *f 2 to 7 mm (0.0787 to 0.2756 in.)
      1. Connect the No. 2 intercooler cooling water hose to the No. 2 intercooler cooling water pipe and slide the clip to secure it.
        NOTE:
        • Make sure to slide the No. 2 intercooler cooling water hose until it contacts the hose stopper of the No. 2 intercooler cooling water pipe.
        • Make sure that the tabs of the clip are within the area shown in the illustration.
  9. CONNECT NO. 4 TURBO WATER HOSE 
    1. GTY1077945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 45°
      *c Paint Mark *d Front Side of Vehicle
      1. Connect the No. 4 turbo water hose to the No. 2 intercooler cooling water pipe and slide the clip to secure it.
        NOTE:
        • Make sure to slide the No. 4 turbo water hose until it contacts the hose stopper of the No. 2 intercooler cooling water pipe.
        • Make sure that the tabs of the clip are within the area shown in the illustration.
  10. CONNECT NO. 5 WATER BY-PASS HOSE (Type A) 
    1. GTY1078409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120°
      *c Paint Mark *d Upper Side of Vehicle
      *e 2 to 7 mm (0.0787 to 0.2756 in.) - -
      1. Connect the No. 5 water by-pass hose to the No. 3 water by-pass pipe and slide the clip to secure it.
        NOTE:
        • Make sure to slide the No. 5 water by-pass hose until it contacts the hose stopper of the No. 3 water by-pass pipe.
        • Make sure that the tabs of the clip are within the area shown in the illustration.
  11. CONNECT NO. 3 WATER BY-PASS HOSE 
    1. GTY1078881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 45°
      *c Paint Mark *d Upper Side of Vehicle
      1. Connect the No. 3 water by-pass hose to the No. 3 water by-pass pipe and slide the clip to secure it.
        NOTE:
        • Make sure to slide the No. 3 water by-pass hose until it contacts the hose stopper of the No. 3 water by-pass pipe.
        • Make sure that the tabs of the clip are within the area shown in the illustration.
  12. CONNECT NO. 1 INTERCOOLER COOLING WATER HOSE 
    1. GTY1078992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 60°
      *c 120° *d Paint Mark
      *e Rear Side of Vehicle *f 2 to 7 mm (0.0787 to 0.2756 in.)
      1. Connect the No. 1 intercooler cooling water hose to the No. 1 intercooler cooling water pipe and slide the clip to secure it.
        NOTE:
        • Make sure to slide the No. 1 intercooler cooling water hose until it contacts the hose stopper of the No. 1 intercooler cooling water pipe.
        • Make sure that the tabs of the clip are within the area shown in the illustration.
  13. CONNECT NO. 1 TURBO WATER HOSE 
    1. GTY1077681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 45°
      *c Paint Mark *d Upper Side of Vehicle
      1. Connect the No. 1 turbo water hose to the No. 1 intercooler cooling water pipe and slide the clip to secure it.
        NOTE:
        • Make sure to slide the No. 1 turbo water hose until it contacts the hose stopper of the No. 1 intercooler cooling water pipe.
        • Make sure that the tabs of the clip are within the area shown in the illustration.
  14. CONNECT NO. 2 FUEL VAPOR FEED HOSE 
  15. INSTALL AIR TUBE ASSEMBLY 
    1. GTY1131530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b Paint Mark
      *c Guide *d 25°
      *e Upper Side of Vehicle *f 2 to 6 mm (0.0787 to 0.2362 in.)
      *g 0 to 5.5 mm (0 to 0.2165 in.) - -
      1. Assemble while matching the paint mark of the air tube hose and the guide of the turbocharger sub-assembly.
      2. Push in until it hits the stopper of the intercooler assembly and using an 8 mm socket wrench to attach the air tube assembly with 4 bolts.

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

      3. Install the air tube assembly and air hose with the 2 clamps.

        Torque: 6.3 N.m (64 kgf/cm, 56 in.lbf) 

        NOTE:

        Make sure that the clamp bolt of the hose clamp are within the area shown in the illustration.

      4. Check that the air hose are securely inserted into turbocharger assembly.
        NOTE:

        Make sure that the air hose are within the area shown in the illustration.

  16. CONNECT PURGE VALVE (NO. 1 VACUUM SWITCHING VALVE ASSEMBLY) 

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

  17. CONNECT ENGINE WIRE 

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

  18. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE 
  19. INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY 

    Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf) 

  20. INSTALL NO. 3 ENGINE COVER 
    Refer to PROCEDURE - Step 55
  21. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 56
  22. ADD COOLANT (for Intercooler) 

    Refer to PROCEDURE - Step 5

  23. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 5

  24. INSPECT FOR COOLANT LEAK (for Intercooler) 

    See step  1

  25. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

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