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Installation Manual

Read this manual prior to the installation.

After installation, follow the instructions for safe use.

Installation must be done by a professional.

※

This application was confirmed by November, 2011.

NOTICE

This manual assumes that you have and know how to use the tools and equipment necessary to safely
perform service operations on your vehicle. This manual assumes that you are familiar with typical
automotive systems and basic service and repair procedures. Do not attempt to carry out the operations
shown in this manual unless these assumptions are correct. Always have access to a factory service manual.
To avoid injury, follow the safety precautions contained in the factory service manual.

REVISION OF MANUAL

Rev. Number

Date

Manual Number

Details

3-3.01 2011/5

E04215-T63010-00

1

st

Edition

3-3.03 2012/11

E04215-T63012-00

Instruction revised

Published in November, 2011 by HKS Co., Ltd. (Unauthorized reproduction is strictly prohibited.)

PRODUCT

GT SUPERCHARGER SYSTEM

PART NUMBER

12001-AT005

APPLICATION

LEXUS LS460

（

DBA-USF40)

ENGINE 1UR-FSE

YEAR

2006/09

～

2009/08

Part No: 12001-AT005 LEXUS LS460 (1UR-FSE)

Kit Installed Vehicle

Kit Installed Engine Compartment

1
2
3
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Содержание 12001-AT005

Страница 1: ...empt to carry out the operations shown in this manual unless these assumptions are correct Always have access to a factory service manual To avoid injury follow the safety precautions contained in the factory service manual REVISION OF MANUAL Rev Number Date Manual Number Details 3 3 01 2011 5 E04215 T63010 00 1st Edition 3 3 03 2012 11 E04215 T63012 00 Instruction revised Published in November 20...

Страница 2: ... be used with the required items listed below Use of inapplicable components will void product warranty Using inapplicable components may cause serious damage to the engine Required Items for HKS GT Supercharger System Complete Kit ECU OEM with most recent factory flash Exhaust Manifold with Catalytic Converter HKS Metal Catalyzer Factory CAT must be modified as well Mid Pipe w Secondary Catalytic...

Страница 3: ...poses HKS will not be responsible for any damage caused by incorrect installation and or use or use after modification and or dismantling of this product This product was designed for installation on a specific JDM factory vehicle The specifications of this product are subject to change without notice The instructions are subject to change without notice Make sure to refer to the most recent instr...

Страница 4: ...acket No 2 1 A 17 G17921 T63030 00 Intercooler Bracket No 3 1 A 18 G90291 062102 BB Blind Nut M6 4 A 19 G17951 T63010 00 Inlet Pipe No 1 1 A 20 G17951 T63020 00 Inlet Pipe No 2 1 A 21 G17951 T63030 00 Inlet Pipe No 3 1 A 22 G17971 T63010 00 Outlet Pipe No 1 1 A 23 G17971 T63020 00 Outlet Pipe No 2 1 A 24 G17971 T63030 00 Outlet Pipe No 3 1 A 25 G17971 T63040 00 Outlet Pipe No 4 1 A 26 G17811 T6301...

Страница 5: ... 082501 CB Cap Bolt M8 L 25 10 B 28 G90121 083002 CB Cap Bolt M8 L 30 2 B 29 G90121 084001 CB Cap Bolt M8 L 40 2 B 30 G90121 086001 CB Cap Bolt M8 L 60 2 B 31 G90121 086501 CB Cap Bolt M8 L 65 1 B 32 G90121 102001 DB Cap Bolt M10 P1 5 L 20 1 B 33 G90121 103501 CB Cap Bolt M10 P1 25 L 35 1 B 34 G90121 103501 DB Cap Bolt M10 P1 5 L 35 1 B 35 G90121 104501 CB Cap Bolt M10 P1 25 L 45 1 B 36 G90121 105...

Страница 6: ...4 G17673 T63010 00 Blow off Pipe No 1 1 B 65 G17673 T63020 00 Blow off Pipe No 2 1 B 66 G13572 T63010 00 Belt 7PK1030 1 B 67 G13572 T63020 00 Belt 6PK2135 1 C 01 G13564 T57010 00 Pulley Cover 2 C 02 G09971 T63020 00 Spacer D 20 d 10 t 16 5 1 C 03 G09971 T63040 00 Spacer D 20 d 8 t 14 5 3 C 04 G09971 T63060 00 Spacer D 15 d 6 t 3 1 C 05 G09971 T57020 00 Spacer D 20 d 10 t 10 5 1 C 06 G09122 K00040 ...

Страница 7: ... 1 D 04 G13565 T63020 00 Idler Pulley Bracket No 2 1 D 05 G15341 T63010 00 Oil Tank Bracket 1 D 06 G17993 T63010 00 Pipe Bracket Hole Dia 12mm 3 D 07 G17714 K00020 00 Pipe Bracket Hole Dia 7mm 1 D 08 G11453 T63010 00 Level Gauge Bracket 1 D 09 G13564 T63010 00 Drive Pulley Bracket 1 D 10 G16293 T63010 00 Water Bypass Joint 1 D 11 G16255 T63010 00 Water Outlet Gasket 2 D 12 90400 078100 Silicone Ho...

Страница 8: ... 00 Intercooler 1 F 01 G17751 T63020 00 Air Cleaner Duct 1 F 02 G17721 T63020 00 Lower Air Cleaner Box 1 F 03 G17722 T63020 00 Upper Air Cleaner Box 1 F 04 G11291 T63050 00 Engine Cover 1 F 05 G09971 T63130 00 Spacer D 10 d 4 t 5 4 F 06 G11293 T63010 00 Engine Cover Bracket 1 F 07 15719 030261 Airtight Tape L 300mm 5 F 08 15719 037100 Sponge Sheet 50 50 3 5 F 09 G11291 T63060 00 Engine Side Cover ...

Страница 9: ...o 1 A24 Outlet Pipe No 3 A23 Outlet Pipe No 2 A25 Outlet Pipe No 4 A01 GTS8550 A04 S C Pulley A05 Fluid Cooler Core A06 Fluid Tank A07 Traction Fluid A11 Hose Assy 10mm A15 I C Bracket No 1 A16 I C Bracket No 2 A17 I C Bracket No 3 Main Parts 1 A02 S C Gasket A26 Suction Pipe A27 S C Bracket No 1 A18 Blind Nut M6 ...

Страница 10: ...e way Valve B62 Airflow Ex Harness B63 6 pin Connector B64 Blow off Pipe No 1 B65 Blow off Pipe No 2 B66 Belt 7PK1030 B67 Belt 6PK2135 B51 F CON Harness F CON Side B52 F CON Harness ECU Side B53 Press Sensor Harness B54 Press Sensor B03 Pipe Bracket B01 Steering ECU Bracket No 1 B02 Steering ECU Bracket No 2 B04 Ground Adapter Main Parts 2 ...

Страница 11: ...Level Gauge Bracket D10 Water Bypass Joint D01 S C Bracket No 2 D03 Idler Pulley Bracket No 1 D02 Tensioner Bracket D04 Idler Pulley Bracket No 2 C1７ 16mm Mesh C11 Water Inlet Adapter C12 O Ring C01 Pulley Cover C10 Idler Pulley φ70 D09 Drive Pulley Bracket D32 Drive Pulley Main Parts 3 D33 Drive Pulley Shaft Assy Bearing C20 Idler Pulley φ85 C19 Idler Pulley φ60 ...

Страница 12: ...R SYSTEM LS460 11 E10 Intercooler F01 Air Cleaner Duct F02 Lower Air Cleaner Box F03 Upper Air Cleaner Box F04 Engine Cover F09 Engine Front Side Cover F10 Engine Left Side Cover F11 Engine Right Side Cover Main Parts 4 ...

Страница 13: ...ve the vehicle at least for 6 minutes after ignition is off to save a memory and setting of the HDD navigator Remove the under covers 3 pieces Remove the engine side covers and engine cover Remove two mounting rubbers in the back of the engine side covers Keep the removed rubbers for later use Remove 6 clips and then remover the cowl top ventilator louver LH ...

Страница 14: ...ft bank Remove the skid control computer assembly Replace the spark plugs with new ones Spark plugs are not included in this kit When replacing the plugs for the 1st 2nd 3rd and 4th cylinder insert a flat head screwdriver into a notch and remove the spark plug tube gasket and ignition coil together Wrap a protection tape around the screwdriver as shown in the diagram on the right Make sure not to ...

Страница 15: ...the left and right sides of the brake ducts Remove the left and right horns and smog sensor Remove the bumper reinforcement Drain coolant Remove the radiator reservoir tank NOTE Take extra care when removing the 10mm fitting used in vehicles manufactured earlier than August 2010 since it is thin and easy to be broken Disconnect the upper and lower radiator hoses ...

Страница 16: ...pulley leaving the belt installed Loosen the auto tensioner and then remove the belt Remove the water pump pulley Remove 2 idler pulleys Remove the resonator bracket Remove the front water bypass joint and 2 water outlet gaskets Remove the water inlet housing and gasket ...

Страница 17: ...installation bracket together Remove the installation bracket from the P S computer Remove the alternator ground and bracket Change the engine harness layout right front bank Remove the corrugated tube of the engine harness circled in the diagram above Remover the harness clamp harness cover and corrugated tube Before Change After Change ...

Страница 18: ...except the black blue wire and wire covered with black tube using the provided 7mm corrugated tube and route it over the cylinder head Re bundle the black blue wire and wire covered with black tube from with the bundle and route it under the VTC unit Black Blue wire Corrugated Tube 5mm 7mm 10mm 13mm Corrugated Tube 5mm 7mm 10mm 13mm After Modification ...

Страница 19: ...cable so they can be inserted between the VTC unit and Water Inlet Adapter P S Computer Bracket No 1 P S Computer Bracket No 2 Ground Adapter Spacer D 20 d 6 t 10 Cap Bolt M6 L 15 3 pcs Cap Bolt M6 L 30 Washer M6 4 pcs Large dia Washer M6 Thermo Sheet 100 100 Tie Wrap S Corrugated Tube 22mm Pipe Bracket No 1 Cover the harness inside the relay block cover with the corrugated tube 22mm Reinstall the...

Страница 20: ...15 Washer M6 Washer M6 L Dia Spacer φ20 φ6 t10 Washer M6 Cap Bolt M6 L 30 Remove the bracket of the alternator ground Secure the bracket to these screw holes Install the P S computer connecter Route the P S computer harness between the bracket and vehicle body Reuse the factory bolts to install the side of the P S computer Relocate the ground to the steering ECU bracket using the Cap Bolt M6 L 15 ...

Страница 21: ...M6 Place the ground in the direction shown in the diagram above to prevent the ground tip from unnecessary contact with the vehicle body Make sure there is no excessive tension on the ECT harness Remove the harness clamp to release tension if necessary Water Inlet Adapter O Ring Factory Bolt M8 x 3 Install the O ring Insert the harness between the VTC unit and Adapter using the 3 factory M8 bolts ...

Страница 22: ...e pulley shaft assembly Place the Drive Pulley and Drive Pulley Shaft over the Water Pump Pulley and install them Water Bypass Joint Drive Pulley Cap Bolt M8 L 25 4 pcs Washer M8 4 pcs Tightening Torque N m kgf m T 21 2 14 Drive Pulley Shaft Assembly Tightening Torque N m kgf m Nut M8 T 21 2 14 Water Temperature Sensor T 21 2 14 Water Outlet Gasket 2 pcs Factory Nut M8 4 pcs ...

Страница 23: ... Pulley Bracket No 2 Idler Pulley Bracket No 2 Spacer D 20 d 8 t 3 2 pcs Spacer D 20 d 8 t 7 Spacer D 20 d 10 t 7 Flat Head Bolt M8 L 30 2 pcs Cap Bolt M8 L 30 Cap Bolt M10 L 95 Washer M8 Washer M10 Spacer D 20 d 10 t 7 Spacer D 20 d 8 t 3 Spacer D 20 d 8 t 3 Spacer D 20 d 8 t 7 Flat Head Bolt M8 L 30 Flat Head Bolt M8 L 30 Cap Bolt M10 L 95 Cap Bolt M8 L 30 ...

Страница 24: ...Fill the space circled in the diagram on the right with cloth or paper to prevent a nut from falling into this gap when installing a pulley later Install the Idler Bearing to Idler Pulley Bracket No 1 Idler Pulley Bracket No 1 Idler Pulley φ60 Hexagon Spacer B 17 M10 L 46 5 Spacer D 20 d 10 t 6 Cap Bolt M10 P 1 5 L 35 Washer M10 Spacer D 20 d 10 t 6 Tightening Torque N m kgf m M10 Bolt T 47 4 79 B...

Страница 25: ...e 22 Flange Nut M10 Tightening Torque N m kgf m M10 Bolt Nut T 43 4 39 Idler Pulley 85mm Idler Pulley 60mm Spacer D 20 d 10 t 4 5 Spacer D 20 d 10 t 7 5 Spacer D 20 d 10 t 6 2 pcs Spacer D 20 d 10 t 14 Cap Bolt M10 P 1 25 L 65 2 pcs Cap Bolt M10 P 1 25 L 70 Washer M10 3 pcs Flange Nut M10 Spacer D 20 d 10 t 6 Cap Bolt M10 L 70 Spacer D 20 d 10 t 6 Cap Bolt M10 L 65 Spacer D 20 d 10 t 4 5 Cap Bolt ...

Страница 26: ...ank Bracket to Idler Pulley Bracket No 1 Install the Fluid Tank Oil Tank Bracket Cap Bolt M6 L 20 2 pcs Washer M6 2 pcs Flange Nut M6 2 pcs Fluid Tank Silicone Hose 70mm L 20 2 pcs Hose Clamp 48 2 pcs Install the 8mm fitting facing to the vehicle s front ...

Страница 27: ...mm and 175mm in length Install the Button Bolt M8 L 20 to the place of the bolt not shown in this diagram Tighten the bolt to the specified tightening torque and then remove it Tightening Torque N m kgf m M8 Bolt T 21 2 14 Cap Bolt M8 L 20 Button Bolt M8 L 20 2 pcs Washer M8 Button Bolt M8 L 20 No washer is required Cap Bolt M8 L 20 Hose 16mm L 500mm O ring ...

Страница 28: ...0mm and 210mm in length Cut the hose to 330mm and 210mm in length Cover a hose with the provided Mesh and secure it with Tie Wraps Pinch the one end of the Mesh push the end inward and interfold the end of the Mesh as shown in the diagrams below Repeat the same procedure to the other end Push and shrink the Mesh in a longitudinal direction to expand the diameter Insert the 16mm Hose into the Mesh ...

Страница 29: ...rim the Mesh surface with scissors Install the 16mm Hose covered with the Mesh Make sure the hoses are not bent and or warped Install the 8mm Hose using the following provided parts Modify the Lower Radiator Hose Cut the hose at 30mm from the radiator side Cut the hose at 5mm from the water inlet housing side Joint Pipe 8mm Hose Clamp 8mm 2 pcs Hose 8mm Cut to 70mm in length from L 3000 Cut 5mm fr...

Страница 30: ...c fan s blade Adjust the installation direction so the hose won t be warped Install the Upper Radiator Hose Bend the Oil Level Gauge Bracket to 55 using pliers as shown in the diagram on the right Secure the Oil Level Gauge using the following provided Parts Level Gauge Bracket Cap Bolt M6 L 15 2pcs Washer M6 2 pcs Flange Nut M6 ...

Страница 31: ...ot allow foreign objects to mix with the Traction Fluid Cut the Hose Assembly 10mm at 730mm from the fluid filter side Make sure to cover the hose end to prevent foreign objects from entering to the hose Cut the Corrugated Tube 15mm to 300mm in length Install the cut Corrugated Tube to the end of the Hose Assembly 10mm Install the Silicone Hose 50mm L 20 to the Fluid Filter Hose Assembly 10mm Corr...

Страница 32: ...ated Tube to 1390mm Hose 8mm Install 1390mm Hose 8mm to the GTS8550 Make sure to cover the hose end to prevent foreign objects from entering to the hose Route the hose installed to the GTS8550 between the engine and Oil Level Gauge Cover the cylinder head cover and vehicle body with cloth to protect them from being damaged then temporality place the GTS8550 on the cylinder head cover GTS8550 Hose ...

Страница 33: ...he VTC cover does not fall Make sure oil does not leak If it does remove the oil Temporarily bolts and spacers to the S C Bracket Cap Bolt M8 L 40 Cap Bolt M8 L 40 Hex Bolt M8 L 40 Spacer D 20 d 8 t 14 5 3 pcs Washer M8 3 pcs S C Bracket No 1 Spacer D 20 d 8 t 14 5 3 pcs Cap Bolt M8 L 60 2 pcs Hexagon Bolt M8 L 60 Washer M8 3 pcs ...

Страница 34: ...e the GTS8550 Tightening Torque N m kgf m T 29 3 00 VTC harness can get out of the opening for the bracket Tighten the S C Bracket with the VTC cover Tightening Torque N m kgf m T 21 2 14 Route the harness between the GTS8550 and cylinder head Suction Pipe S C Bracket No 2 Gasket 2 pcs Collar D 15 d 6 t 3 Cap Bolt M6 L 25 3 pcs Flange Nut M6 Cap Bolt M8 L 60 Cap Bolt M8 L 60 Low Head Cap Bolt M8 L...

Страница 35: ... Install Tie Wraps as shown above Cut the factory blow by hose at the position the arrow points in the diagram Cut the Hose 16mm to 135mm and install the cut hose Mounting Bolt Reuse Flange Nut M6 Hose 16mm 150mm Joint Pipe 12 16 12mm Hose Clamp 16mm 2 pcs Tie Wrap M 2 pcs Tie Wrap L 6 pcs Hose Clamp 10mm 2 pcs Do not install a Tie Wrap over the place the arrow points in the diagram above to avoid...

Страница 36: ...o the oil tank with Tie Wraps Install the Tensioner Pulley to the Tensioner Pulley Bracket Tie Wrap M Tie Wrap S Tightening Torque N m kgf m M10 Bolt T 47 4 79 Idler Pulley 70mm Pulley Cover Tensioner Pulley Bracket Spacer D 20 d 10 t 10 5 Cap Bolt M10 L 45 Washer M10 Flange Nut M10 Tie Wrap M Tie Wrap S Use this hole to secure the harness Spacer D 20 d 10 t 10 5 ...

Страница 37: ...lt 7PK1030 Temporarily install the bearing holder to the Drive Pulley Bracket Nut Plate M10 Spacer D 20 d 10 t 5 Cap Bolt M8 L 20 Cap Bolt M10 L 35 Washer M8 Washer M10 Plate Nut M10 Belt 7PK1030 Drive Pulley Bracket Cap Bolt M8 L 25 4 pcs Washer M8 4 pcs Cap Bolt M8 L 20 Cap Bolt M10 L 35 Washer M8 Washer M10 Spacer D 20 d 10 t 5 ...

Страница 38: ...er D 20 d 8 L 37 2 Spacer D 20 d 10 L 39 5 Cap Bolt M8 L 65 Cap Bolt M10 L 20 Cap Bolt M10 L 65 Washer M8 Washer M10 Nut M10 Place the Spacer D 20 d 10 L 39 5 under the belt Spacer D 20 d 10 L 39 5 Cap Bolt M10 L 65 Washer M10 Nut M10 Spacer D 20 d 8 L 37 2 Cap Bolt M8 L 65 Cap Bolt M10 L 20 Washer M8 Tighten the Nut M10 with Plate Nut M10 Flange Part ...

Страница 39: ...ly appropriate tension to the belt Install the S C Pulley to the GT8550 Install the Idler Pulley Tightening Torque N m kgf m M8 Bolt T 21 2 14 M10 Bolt T 47 4 79 S C Pulley Low Head Cap Bolt M6 L 12 5 pcs Tightening Torque N m kgf m M6 Bolt T 12 1 22 Installing the Belt 7PK1030 with the pulley to the GT8550 Idler Pulley 70mm Pulley Cover Spacer D 20 d 10 t 16 5 Cap Bolt M10 L 55 Flange Nut M10 Was...

Страница 40: ... stroke the Pulley 70mm clockwise centering Bolt 1 Tighten Bolt 2 and secure the stroke Tighten Bolt 2 and secure the tensioner Tightening Torque N m kgf m M10 Bolt T 47 479 Measure the belt tension at the point shown in the diagram above Tension Meter Settings Span Length 230mm No of Ribs 7 Belt SG 0 0188g 1 rib x 1m long Tension 960N ...

Страница 41: ...TERCOOLER FLUID COOLER CORE Remove the outside temperature sensor from the reinforcement Install the Blind Nuts on the center line of the reinforcement s bottom toward the vehicle front as shown below Blind Nut M6 4 pcs 50mm 100mm 75mm 80mm Front of Vehicle ...

Страница 42: ... a belt sander Paint the modified part of the bracket s bottom matte black Drill a 9 1mm pilot hole Install the Blind Nut using a nut fastener Recommended Tool POP MN10A S L PNT110 There is a mark by a punch in the circled position Use this mark as a center line of the reinforcement to drill pilot holes Driver s side LHD Passenger s side LHD ...

Страница 43: ... Remove the harness cover from the back of the hood lock Harness Cover Push the A C pipe to rear vehicle body and secure the pipe to bracket on the vehicle side using Tie Wraps Tie Wrap L Tie Wrap M Corrugated Tube 15mm Cut to 120mm Corrugated Tube 10mm Tie Wrap L Tie Wrap M Secure any loose harness with Tie Wraps ...

Страница 44: ...r brass Cover the A C condenser and intercooler to protect from being damaged Pull the lower side of the center brass forward insert and temporarily install the intercooler Install the factory bolts to the lower side of the center brass Cap Bolt M6 L 15 2 pcs Large diameter Washer M6 2 pcs Intercooler Intercooler Bracket No 1 Cap Bolt M8 L 15 2 pcs Washer M8 2 pcs ...

Страница 45: ... using the Button Bolt M8 L 20 Intercooler Bracket No 2 Intercooler Bracket No 3 Spacer D 20 d 9 t 5 7 pcs Cap Bolt M6 L 25 4 pcs Cap Bolt M6 L 25 Cap Bolt M8 L 30 Button Bolt M8 L 20 Flange Nut M8 Washer M6 4 pcs Washer M8 3 pcs Install Intercooler Bracket No 2 with the Intercooler to the Oil Cooler Core inserting the Spacer D 20 d 9 t 5 using the Cap Bolt M8 L 25 Washer M8 and Flange Nut M8 ...

Страница 46: ...ercooler using the Cap Bolt M8 L 30 and Washer M8 Insert 4 Spacers D 20 d 9 t 5 and install the intercooler to the reinforcement using the Cap Bolts M6 L 25 and M6 Washers Connect to the S C 8mm L 1390 Connect to the oil tank Connect the 880mm long φ15 Corrugated tube to 1440mm long φ8 tube Route the hose through the place the arrow indicated in the diagram above to pull into the engine Hose 8mm H...

Страница 47: ...6 Install both sides horns and smog sensor Secure the hose to the electric fan After securing the hose to the electric fan connect the hose to the oil tank Secure the hose to the side of the rib to avoid contact with the reservoir tank ...

Страница 48: ... 8 INSTALLATION OF INTERCOOLER PIPE Install the provided Insulator Rubber to Pipe Bracket No 1 Inlet Pipe No 1 Inlet Pipe No 2 Inlet Pipe No 3 Outlet Pipe No 1 Outlet Pipe No 3 Outlet Pipe No 2 Outlet Pipe No 2 Insulator Rubber Retainer ...

Страница 49: ...alling the pipe Install the Pipe Bracket with a 7mm hole to Inlet Pipe No 1 Temporarily install Inlet Pipe No 1 Temporarily install Inlet Pipe No 3 Place the shorter straight portion to the intercooler side See the diagram below Inlet Pipe No 3 Silicone Hose 65mm L 70 Hose Clamp 44 2 pcs Silicone Hose 60mm 65mm Hose Band 40 Hose Band 36 Cap Bolt M6 L 30 Washer Large dia M6 Flange Nut M6 ...

Страница 50: ...ot come in contact with the harnesses from the relay box Tighten all bolts nuts and hose clamps temporarily installed Make sure all installed parts do not come in contact with any other parts of the vehicle Pipe Bracket Hole Dia 12mm Inlet Pipe No 2 Silicone Hose 65mm L 70 2 pcs Silicone Hose 65mm L 20 Hose Clamp 40 5 pcs Hole Dia 12mm Install the Silicone Hose 65mm L 20 to the pipe Temporarily in...

Страница 51: ...stalling the pipe Temporarily install Outlet Pipe No 1 Place the shorter straight portion to the intercooler side See the diagram below Install the Pipe Bracket to the front cross member Outlet Pipe No 1 Silicone Hose 65mm L 70 Hose Clamp 44 2 pcs Pipe Bracket Hole Dia 12mm 2 pcs Hole Dia 12mm ...

Страница 52: ...tall Outlet Pipe No 4 Outlet Pipe No 2 Silicone Hose 65mm L 70 Silicone Hose 65mm L 20 2 pcs Hose Clamp 40 4 pcs Outlet Pipe No 4 Silicone Hose 70mm 80mm Silicone Hose 80mm L 70 Hose Clamp 44 Hose Clamp 48 2 pcs Hose Clamp 56 Outlet Pipe No 3 Silicone Hose 65mm L 70 Hose Clamp 40 2 pcs Install the Silicone Hose 65mm L 20 to the pipe Temporarily install the pipe to the Pipe Bracket using the Hose C...

Страница 53: ... it does not come in contact with the electric fan connector Secure the electric fan harness to the electric fan s rib Tighten all bolts nuts and hose clamps temporarily installed Make sure all installed parts do not come in contact with any other parts of the vehicle Tie Wrap M ...

Страница 54: ... No 1 Adjust the position of Blow off Pipe No 1 so it does not come in contact with the drive pulley bracket cap bolt M10 Secure Blow off Pipe to Outlet Pipe No 4 using Tie Wraps Blow off Valve Blow off Pipe No 2 Silicone Hose 35mm L 55 2 pcs Hose Clamp 20 4 pcs Blow off Pipe No 1 Silicone Hose 35mm L 55 2 pcs Hose Clamp 20 4 pcs Tie Wrap L ...

Страница 55: ...HKS GT SUPERCHARGER SYSTEM LS460 54 Secure the Traction Fluid Hose to Outlet Pipe No 4 Tie Wrap L Tie Wrap M ...

Страница 56: ...ess colors are as follows from the left viewing from the terminal insert Black Blue Brown Black Black White Black Red Make a note if the color order is different Insert the compact precision screwdriver into the hole and pull out the retainer white resin part Insert the flathead precision screwdriver into the both sides gap Move the screwdriver up and down to make the gap larger Remove the front h...

Страница 57: ...the removed terminal to the 6 Pin connector Insert the Airflow Extension Harness terminal to the factory airflow connecter Reinstall the removed retainer and front holder Secure the harness using the Tie Wrap 6 Pin Connector Airflow Extension Harness Red Blue Yellow Green White Tie Wrap L ...

Страница 58: ...the position shown in the diagram on the lower left and connect the hoses using the 12mm Joint Hose Vacuum Piping Cut the canister purge hose Insert the One Way Valve between the hose secure the valve using Tie Wraps Joint Pipe 12mm Tie Wrap M Stock Blow by Hose Flow Direction Flow Direction One Way Valve Tie Wrap S ...

Страница 59: ...e 4mm Hose to 200mm in length Install the 200mm long 4mm Hose to the T Fitting 4 4 4mm Install the Hose 6mm and Joint Pipe 4 6mm to the Pressure Sensor Cut the Hose 4mm to 780mm in length and install the cut hose to the Joint Pipe 4 6mm Install the Air Filter 4mm to the Hose 4mm Install the Pressure Sensor to the harness bracket Connect the Air Filter 4mm to the 500mm long Hose 4mm T Fitting 8 4 8...

Страница 60: ...ating Piping Cut the Hose 6mm to 425mm in length and install the cut hose to the 200mm long Hose 4mm Secure the Hose 6mm to the A C hose and engine harness using Tie Wraps Joint Pipe 4 6mm Hose 6mm Hose Clamp 6mm 2 pcs Tie Wrap S Tie Wrap M Tie Wrap L ...

Страница 61: ...U side s F CON Harness Cut two tie wraps and remove the white resin Remove the cover of the ECU case F CON Harness ECU Side Disconnect the ECU connectors 6 pcs from the case Disconnect the ECT connectors 4 pcs Disconnect the relay connectors 2 pcs from the white resin case Disconnect the connector from the case ...

Страница 62: ... After installing the F CON Harness connect the ECT connector Ref After the ECT was removed Modify the ECU box so the harness can be routed Reinstall the box Route the F CON Harness as shown above Mount the VAC using a double sided tape ...

Страница 63: ... lining Pull the ECU side s F CON Harness and Pressure Sensor Harness into the vehicle interior from the grommet next to the battery Route the F CON iS Communication Cable terminal between the center tunnel and blower unit from the driver s side to passenger s side Insulate the white and brown terminals of the F CON iS Communication Cable Pressure Sensor Harness F CON iS Comm Cable ...

Страница 64: ...ed with black Tie Wraps Release the locks on both sides of the connector Lift the cover Release the locks on both sides of the connector Lift the cover Connect the red blue wire of the OSC Harness to No 43 port of the connector Press the cover until it is locked Connect the yellow wire to No 37 port of the connector green wire to No 38 port of the connector Press the cover until it is locked ...

Страница 65: ...d wrong connection may cause damage not only to the F CON iS but also to fuses of the vehicle F CON Connector viewed from the insertion 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 Connect the OSC Harness connector to the F CON side s harness ...

Страница 66: ...ector Connect F CON iS Communication Cable connectors to the terminal of the diagnosis system Connect the OSC to the harness Connect two of the F CON iS to the harness Modify the foam board on a front seat foot area of a passenger compartment and store the F CON iS OSC and INJ Adapter in the board as shown in the diagram on the right INJ Adapter 2 pcs F CON iS 2 pcs OSC ...

Страница 67: ...on board display connect the AV output cable to the terminal of the F CON iS connected to the F CON harness tied with black Tie Wraps and connect the display switch to the terminal AV output cable is not included in the kit The F CON iS included in this kit has no function to change the items can be shown on the display ...

Страница 68: ...N Connecting Cable or hexode four core straight module cable must be prepared separately Reinstall the entrance molding of the passenger s side and side cover of the front seat foot area lining of a passenger compartment NOTE When installing the side cover make sure not to pinch the F CON harness Connect the Pressure Sensor Harness connector Reinstall the battery Do not reconnect the cable ...

Страница 69: ... bumper reinforcement Reinstall the front bumper NOTE Make sure the fug light bracket does not come in contact with the fog light and cause damage to the light Cut the factory hose 8mm to 25mm to 30mm and install the cut hose to the thermo housing Reinstall the radiator reservoir tank ...

Страница 70: ...e Lower Air Cleaner Box Install the Lower Air Cleaner Box Install 2 airflow sensors to the Upper Air Cleaner Box Lower Air Cleaner Box Mounting Rubber 3 pcs Retainer 3 pcs Cap Bolt M6 L 25 3 pcs Washer M6 Large Dia 3 pcs Upper Air Cleaner Box Cap Bolt M4 L 15 4 pcs Spacer D 10 d 4 t 5 4 pcs Washer M4 4 pcs ...

Страница 71: ... Connect the airflow sensor connector NOTE Connect connector of right bank side to the sensor of right bank side and the connector of left side bank to the sensor of left bank side If the connectors are connected to the wrong sides the fuel management will have a problem and the engine might be damaged Silicone Hose 70mm L 55 Hose Clamp 44 2 pcs Button Bolt M5 L 15 3 pcs CAUTION ...

Страница 72: ...ixed with Traction Fluid can lead to damage to the Supercharger Assy Make sure that there are no foreign objects in the traction tank Add 450cc of Traction Fluid to the Oil Tank up to the dotted line in the diagram Close the cap properly and securely Prepare 5 litters of engine coolant Pour engine coolant to the reservoir tank referring to the instruction on the tank Reconnect the cables to the ba...

Страница 73: ...ake sure all hose clamps are tighten properly 11 Make sure all bolts and nuts are tightened 12 Make sure all installed components are secured 13 Make sure the negative cable terminal is securely attached to the battery 14 Make sure the engine oil level dipstick is between H L The supplied F CON iS unit is pre programmed Prepare 130cc of Traction Fluid in a beaker or small container open the oil ca...

Страница 74: ...as necessary If there is excess Traction Fluid remaining in the bottle replace the cap on the bottle and store in a safe location Always store excess Traction Fluid in the original bottle Put the traction oil tank cap back on Bleed air out of engine coolant referring to the instruction on the tank Items to confirm Check 1 Make sure the Traction Fluid returns to the Oil Tank 2 Make sure Power LED o...

Страница 75: ... of Rig 7 Belt SG 0 0188g rib 1m Tension 960N 18 INSTALLTION OF AIR CLEANER DUCT Install the front engine side cover Install the factory mounting bolt to the Engine Cover Bracket Install the Engine Cover Bracket to the Air Cleaner Duct Engine Cover Bracket Mounting Bolt Reuse Flange Nut M6 Front Engine Side Cover Air Cleaner Duct Tie Wrap L Sponge Sheet 30 30 t3 Cut to half Affix the sponge sheet ...

Страница 76: ...ing the vehicle from the lift The vehicle height will return to the standard position after a few minutes Set up the back guide monitor Procedure 1 Fully turn the steering wheel to the right 2 Fully turn the steering wheel to the left When setup is completed the projected route will appear on the back monitor Bleed air from the engine coolant Make sure the A C heater works properly Readjust the be...

Страница 77: ...gine Cover lift the mounting rubbers instead of the engine cover itself to prevent the cover from being damaged Engine Cover Clip Reuse x 5 Install the mounting rubbers removed from the factory engine cover to back of the Engine Cover 2 points Insert the mounting rubbers to the mounting bolts Install the Engine Cover Clip Reuse x 5 ...

Страница 78: ...HKS GT SUPERCHARGER SYSTEM LS460 77 Install both left and right Engine Side Covers The installation process is now complete Engine Side Cover Left Engine Side Cover Right Clip Reuse 8 pcs ...

Страница 79: ...ping loose hose clamps of the following points Connection point to the Supercharger Connection point to the oil cooler Connection point to the oil tank Connection point to the oil filter Signs of damage due to rubbing of the Traction Oil hose to other parts Cracks or breaks in the Traction Oil hose If Traction Oil filled to the marking level on the oil level gauge 3 Belt Inspection Check if belts ...

Страница 80: ...the HKS GT Supercharger Use the part number below to order the Traction Oil Filter Belts are consumable parts Always check belts prior to driving for any cracks or tears Replace damaged belts immediately Use the part number below to order the Ribbed Belt Traction Oil does not need to be replaced however check oil level prior to driving If oil level is low add Traction Oil as necessary Product Name...

Страница 81: ...s on the belt Replace damaged belts immediately Engine output feels weak At full throttle the boost starts to reduce at a certain RPM while engine RPM is increasing Air filter worn out Replace the filter element If HKS Hybrid Filter was used for more than 10 000km replace the filter element Replace the element even it s used less than 10 000km depending on the filter condition Bad connection Groun...

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