PHR 4.5” Intercooler Install
These instructions feature these products (not all these products are provided in the kit):
- 4.5" intercooler
- hot and cold side intercooler pipes
- Tial Q Blow Off Valve (BOV)
- 40 inches of 1/4in vacuum hose
- 1/4in vacuum tee
- assorted worm clamps and silicone couplers
Step 1:
refer to the Toyota workshop manual to remove the front bumper cover (not shown), front crash bar, plastic air diverter trim panel, and the OE Coolant overflow reservoir, power steering line mounting bolts, and OE condenser fan.
Step 2:
Reinstall power steering mounting bolts and gently bend power steering lines towards a/c condenser to make clearance for intercooler.
Step 3:
Find and position something suitable to support the new intercooler for install (detailing seat shown) and set the intercooler onto your support positioned in previous step.
Step 4:
Using a tie strap, temporarily move and strap the hood release cable up and away from intercooler so that it will not be in the way or become pinched by intercooler during install.
Step 5:
Move intercooler into position and align mounting tab holes with the existing holes in radiator support below hood latches.
Step 6:
while holding supplied intercooler mount spacer in place, install the supplied M6 bolt of appropriate length. Then slide intercooler onto mounting bolt and loosely screw on the M6 locking nut. do for both sides.
(Upper mounting bolt size: M6 - 1.0 x 30 Cap Screw)
Step 7:
Remove whatever support you are using, and allow inter cooler to hang from M6 mounting bolts installed during previous step.
Step 8:
Loosely install lower intercooler support bracket using supplied bolts and push/pull intercooler into position so that it is not tilted inwards or outwards, but rather straight up and down. use a leveling device to make an more accurate position. once intercooler is in the desired position, tighten the lower support bolt, then the upper mounting bolts. check and correct position if needed.
Step 9:
Route hood latch cable and bracket and mount using tie straps and factory mounting nut and bolt in existing hole in radiator support.
Step 10:
Using an appropriate tool, bend the tabs on frame rail near the intercooler inlet and outlet to gain clearance for charge pipe coupler. repeat on both sides.
Step 11:
Loosely install couplers onto both inlet and outlet of intercooler. The 2.5in to 3in adapter coupler goes on the intercooler inlet (sometimes called hot side or turbo discharge side).
Step 12:
Loosely install turbo discharge pipe and route it under the sway bar. Make sure it is routed so that it will not come into contact with anything, such as: the alternator, power steering rack or lines, sway bar, or misc. wiring. Rotating the turbo compressor housing will most likely be required for proper charge pipe routing.
Step 13:
At first loosely install intercooler inlet charge pipe onto turbo discharge pipe and then into the intercooler inlet coupler. Once properly in position and with adequate clearance tighten all 6 supplied clamps as well as turbo compressor housing mounting bolts so it can no longer rotate.
Step 14:
On left side remove a/c line to frame rail mounting bolts and lower the line down for easier access.

Step 15:
Using a large pair of vice grip pliers clamp down on the a/c line fittings so that you may remove there mounting brackets without releasing/discharging the a/c system.
Step 16:
While clamped in the vice grips remove the factory m6 nut and mounting bracket. Then install the M6 bolt acquired in previous step along with factory M6 flange nut and tighten.
Step 17:
Remove vice grip pliers and repeat on the other a/c line. below is a view of M6 bolts installed and factory a/c line mounting brackets removed.
Step 18:
Gently bend a/c lines down to gain clearance for charge pipes.
Step 19:
Depending on your model year of Supra as well as whether its auto or manual transmission you may have a radiator fan connector that needs to be repositioned for clearance. Remove it with its mounting clip from the radiator fan bracket
Step 20:
Remove the top mounting bolt of the radiator fan bracket and move fan bracket slightly to slip fan electrical connector onto opposite side of fan bracket and re clip in place using same clip hole in bracket. Reinstall top mounting bolt of fan bracket. If additional clearance is required in the following steps some grinding/material removal of the factory radiator fan bracket my be required.