Introduction

Upgrading the intercooler on a supercharged Lexus IS-F is one of the most effective modifications you can make to improve both power and reliability. The factory intercooler on the 2UR-GSE engine was designed for moderate boost levels and can become a bottleneck once you push the supercharger harder. The Greddy intercooler kit addresses this by offering a larger core, better heat dissipation, and improved flow characteristics. Whether you're chasing higher horsepower numbers at the track or simply want a more consistent daily driver, this step-by-step guide will help you complete the installation correctly the first time.

Before beginning, note that this guide assumes your IS-F is already equipped with a supercharger system. The Greddy intercooler is specifically designed to work with popular supercharger kits such as the Greddy or HKS units, but the installation process is similar across most forced-induction setups. Always refer to your specific kit instructions for any model-specific variations.

Tools and Materials Required

Having everything on hand before you start will save time and frustration. The Greddy intercooler kit typically includes the new intercooler core, mounting brackets, silicone hoses, and necessary hardware. You will also need the following tools and supplies:

  • Greddy intercooler kit (verify it matches your supercharger model)
  • Socket set (metric, 8mm–19mm) with extensions
  • Combination wrench set
  • Torque wrench (capable of reading in in-lbs and ft-lbs)
  • Flathead and Phillips screwdrivers
  • Hose clamp pliers or a flathead screwdriver for adjusting clamps
  • Radiator hose removal tool (if necessary)
  • Coolant catch pan (if draining coolant)
  • Distilled water and compatible coolant
  • Rags and shop towels
  • Safety glasses and mechanics gloves
  • Battery terminal wrench
  • Jack and jack stands (for better access, though not strictly required)
  • Trim panel removal tool (if removing bumper cover)

Preparation: Getting Your IS-F Ready

Proper preparation prevents problems and ensures you can work safely. Follow these steps to make the job easier:

  1. Park on a level surface and engage the parking brake. If you plan to remove the front bumper, you may also want to raise the front slightly with jack stands for better access.
  2. Disconnect the battery (negative terminal first) to avoid any electrical shorts or accidental activation of cooling fans.
  3. Let the engine cool completely. The intercooler system can retain heat even after the engine is off; a warm system increases the risk of burns and makes hose removal more difficult.
  4. Drain the coolant (if your intercooler setup uses a water-to-air system). Locate the intercooler coolant drain plug or loosen the lower radiator hose to drain fluid into a clean catch pan. Dispose of coolant properly.
  5. Remove any interfering components. On many IS-F installations, you will need to remove the front bumper cover, grille, and possibly the crash bar to access the intercooler. Consult your supercharger kit documentation for the exact procedure. Keep all fasteners organized in labeled bags.

Removing the Factory Intercooler

With the front of the car opened up, you can now remove the stock intercooler. The process may vary slightly depending on your supercharger setup, but the general steps are consistent:

  • Locate the stock intercooler – it will be mounted between the supercharger outlet and the throttle body (in a water-to-air setup) or in the front bumper opening (air-to-air). For most IS-F supercharger kits, the intercooler is a front-mount air-to-air unit.
  • Remove the intake piping that connects to both sides of the intercooler. Loosen the hose clamps with a screwdriver or socket and gently pull the hoses off. If they are stuck, use a twisting motion and a bit of penetrating oil.
  • Disconnect any electrical connectors attached to the intercooler, such as temperature sensors or charge air cooler pumps. Carefully unclip them and set wiring aside.
  • Unbolt the intercooler mounting brackets. Use a socket wrench to remove the bolts securing the intercooler to the chassis or intercooler support structure. Keep the bolts as you may reuse them with the Greddy kit.
  • Lift the stock intercooler out of the engine bay or front bumper opening. Take care not to bend the fins or damage the cooler. Inspect the condition of the old unit – note any oil residue (which could indicate a boost leak) or damaged fins.

Once the factory intercooler is removed, clean the mounting area and inspect the hoses for cracks. This is a good time to replace any worn silicone couplers.

Installing the Greddy Intercooler

Now you’re ready to install the Greddy unit. Follow these steps for a proper fitment:

  • Position the Greddy intercooler in the same location as the stock unit. The Greddy kit is designed to be a direct fit, but you may need to adjust the mounting brackets slightly. Dry-fit the intercooler before tightening anything.
  • Secure the intercooler using the supplied brackets and bolts. Torque the mounting bolts to the manufacturer’s specification (typically 8–10 ft-lbs for small bracket bolts). Do not overtighten, as this can distort the core or crack the end tanks.
  • Attach the silicone hoses provided with the Greddy kit. Use the new hose clamps included in the package. Ensure each hose slides fully onto the intercooler inlet/outlet and that the clamps are positioned over the barbed section of the pipe.
  • Reconnect the intake piping to the other end of the hoses. On most supercharged IS-F setups, one side connects to the supercharger outlet and the other to the throttle body. Tighten all clamps evenly – aim for 5–6 Nm (45–50 in-lbs) to prevent leaks without cutting the hose.
  • Reattach any electrical connectors that were disconnected. If your intercooler has an integrated temperature sensor, make sure the wiring is routed away from moving parts and sharp edges.
  • Double-check all connections before moving on. Wiggle the intercooler to ensure it is stable; there should be no excessive movement.

For air-to-water intercooler setups, you will also need to fill the intercooler coolant system with a 50/50 mix of distilled water and ethylene glycol coolant. Bleed the system by running the engine with the cap off until air bubbles stop.

Finalizing the Installation

Now that the intercooler is in place, you need to reassemble the vehicle and verify the system is leak-free:

  1. Reinstall any removed body panels (grille, bumper cover, crash bar, splash shields). Ensure all clips and bolts are secure to avoid rattles.
  2. Reconnect the battery (positive first, then negative).
  3. Refill coolant if you drained the intercooler system. Run the engine with the radiator cap off, if applicable, to bleed air. For air-to-air systems, no coolant is needed.
  4. Start the engine and let it idle for 5–10 minutes. Watch for any coolant or boost leaks at the intercooler connections. Listen for hissing sounds that indicate a leak.
  5. Test drive the vehicle under light loads first. Gradually increase boost pressure while monitoring intake air temperatures and boost gauge (if equipped). A proper intercooler install should show lower IATs and no change in boost pressure.

After the test drive, re-check all clamps and bolts while the engine is off. It is normal for silicone hoses to settle slightly, so you may need to re-tighten clamps after the first heat cycle.

Maintenance and Long-Term Care

To keep your Greddy intercooler performing at its peak, follow these maintenance practices:

  • Inspect couplings and clamps every oil change. Look for cracks, splits, or loose worm gears that can cause boost leaks.
  • Clean the intercooler core annually. Road debris, bugs, and oil film can clog the fins and reduce heat exchange. Use a gentle degreaser and low-pressure water to flush from the back side. Avoid bending the fins with high-pressure washers.
  • Check for physical damage after any road debris impact. A bent fin or cracked tank will significantly reduce efficiency.
  • Monitor engine performance – if you notice a loss of power or rising intake temperatures, inspect the intercooler for internal blockages or leaks.
  • Replace silicone hoses every 5 years or if they feel hard or brittle. UV exposure and heat cycles eventually degrade rubber compounds.

For additional tuning advice and community feedback, consult the ClubLexus IS-F forum and the official Greddy performance website. Many owners share their installation experiences and post-intercooler dyno results that can help you dial in your setup.

Conclusion

Installing a Greddy intercooler on your supercharged Lexus IS-F is a straightforward upgrade that delivers measurable gains in power and reliability. By following the steps outlined above—proper preparation, careful removal of the factory unit, precise installation of the Greddy kit, and thorough testing—you can ensure your vehicle enjoys lower intake air temperatures and consistent performance under boost. Regular maintenance will keep the intercooler working efficiently for years. Whether you're a weekend warrior or a daily driver, this upgrade is one of the best investments you can make for your IS-F’s forced induction system.