Lexus IS250 IS220d GSE20 ALE20 2AD-FHV INTAKE

INSTALL INTERCOOLER ASSEMBLY

CONNECT COOLER CONDENSER ASSEMBLY

CONNECT NO. 3 AIR HOSE

CONNECT RADIATOR OUTLET HOSE

CONNECT VACUUM TRANSMITTING HOSE

INSTALL NO. 2 AIR HOSE

INSTALL AIR TUBE

INSTALL RADIATOR INLET HOSE

INSTALL UPPER RADIATOR SUPPORT

INSTALL HOOD LOCK ASSEMBLY

INSTALL HOOD LOCK CONTROL CABLE COVER

INSTALL RADIATOR RESERVE TANK

INSTALL FRONT BUMPER ENERGY ABSORBER

INSTALL FRONT BUMPER ASSEMBLY

ADD ENGINE COOLANT

CHECK FOR ENGINE COOLANT LEAKAGE

INSTALL ENGINE UNDER COVER

INSTALL NO. 1 ENGINE COVER

INSTALL NO. 1 AIR CLEANER INLET

INSTALL COOL AIR INTAKE DUCT SEAL

INTERCOOLER - INSTALLATION

1. INSTALL INTERCOOLER ASSEMBLY

Install the intercooler with the 4 bolts.

Torque:
6.0 N*m{ 62 kgf*cm, 54 in.*lbf}

Install the vacuum transmitting pipe to the fan assembly with the 3 bolts.

Torque:
6.0 N*m{ 61 kgf*cm, 53 in.*lbf}

Install the radiator outlet hose to the radiator assembly and secure it with the clip.

HINT:

Make sure that the claws on the clips are positioned as shown in the illustration.

2. CONNECT COOLER CONDENSER ASSEMBLY

Install the radiator assembly to the vehicle together with the intercooler and the cooling fan assembly.

NOTICE:

Make sure that the cooler condenser assembly and radiator assembly do not come into contact with each other.

Install the cooler condenser assembly to the radiator assembly with the 4 bolts.

Torque:
5.0 N*m{ 51 kgf*cm, 44 in.*lbf}

3. CONNECT NO. 3 AIR HOSE

Install the No. 3 air hose to the intercooler and secure it with the clip.

HINT:

Make sure that the claws on the clip are positioned as shown in the illustration.

4. CONNECT RADIATOR OUTLET HOSE

Install the radiator outlet hose to the radiator assembly and secure it with the clip.

HINT:

Make sure that the claws on the clip are positioned as shown in the illustration.

5. CONNECT VACUUM TRANSMITTING HOSE

Install the vacuum transmitting hose to the vacuum transmitting pipe and secure it with the clip.

HINT:

Make sure that the claws on the clip are positioned as shown in the illustration.

6. INSTALL NO. 2 AIR HOSE

Install the No. 2 air hose to the intercooler and secure it with the clip.

HINT:

Make sure that the claws on the clip are positioned as shown in the illustration.

7. INSTALL AIR TUBE

Install the air tube to the intercooler and secure it with the 2 clips.

HINT:

Make sure that the claws on the 2 clips are positioned as shown in the illustration.

8. INSTALL RADIATOR INLET HOSE

Install the radiator inlet hose to the radiator assembly and secure it with the 2 clips.

HINT:

Make sure that the claws on the 2 clips are positioned as shown in the illustration.

9. INSTALL UPPER RADIATOR SUPPORT

Install the upper radiator support with the 5 bolts.

Torque:
8.0 N*m{ 82 kgf*cm, 71 in.*lbf}

Install the 6 wire harness clamps and the No. 2 engine room wire.

Connect the clamp and the 2 cooling fan motor connectors.

Connect the 4 wire harness clamps and the 2 connectors.

10. INSTALL HOOD LOCK ASSEMBLY

Install the 2 bolts and the hood lock assembly to the upper radiator support.

Torque:
8.0 N*m{ 82 kgf*cm, 71 in.*lbf}

Install the hood lock nut and the hood lock nut cap.

Torque:
8.0 N*m{ 82 kgf*cm, 71 in.*lbf}

Connect the connector.

11. INSTALL HOOD LOCK CONTROL CABLE COVER

Connect the clamp and install the hood lock control cable cover with the 3 screws.

12. INSTALL RADIATOR RESERVE TANK

Install the radiator reserve tank to the upper radiator support with the 2 bolts.

Torque:
5.0 N*m{ 51 kgf*cm, 44 in.*lbf}

Install the reserve tank hose to the radiator reserve tank and secure it with the clip.

HINT:

Make sure that the claws on the clip are positioned as shown in the illustration.

Install the reserve tank outlet hose to the radiator reserve tank and secure it with the clip.

HINT:

Make sure that the claws on the clip are positioned as shown in the illustration.

13. INSTALL FRONT BUMPER ENERGY ABSORBER

14. INSTALL FRONT BUMPER ASSEMBLY

15. ADD ENGINE COOLANT

Tighten all the plugs.

Torque:
for cylinder block drain cock plug:
20 N*m{ 204 kgf*cm, 15 ft.*lbf}

Add engine coolant.

Specified capacity:
8.9 liters (9.4 US qts, 7.8 lmp. qts)

HINT:

The coolant reserve tanks of TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology that consists of a combination of low phosphates and organic acids).

Contact your TOYOTA dealer for further details.

Slowly pour coolant into the radiator reservoir until it reaches the FULL line.

Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

If the coolant level is low, add coolant.

Install the radiator cap.

Bleed air from the cooling system.

NOTICE:

Before starting the engine, turn the A/C switch off.

Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.

HINT:

The thermostat open timing can be confirmed by squeezing the inlet radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose.

NOTICE:

When squeezing the radiator hose:

Wear protective gloves.

Be careful as the radiator hoses are hot.

Keep your hands away from the radiator fan.

Maintain the engine speed at 2,000 to 2,500 rpm.

Squeeze the inlet and outlet radiator hoses several times by hand to bleed air from the system.

NOTICE:

When squeezing the radiator hoses:

Wear protective gloves.

Be careful as the radiator hoses are hot.

Keep your hands away from the radiator fan.

Stop the engine and wait until the engine coolant cools down to ambient temperature.

CAUTION:

Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.