00602-17620-3xx TRD 1mz Supercharger Manual

24
Installation Instructions for 3.0-liter V6 Supercharger Kit 1997-2000 Camry,1999-2000 Solara, 1997-1999 Avalon Supercharger Kit Part Numbers:00646-17620-301 00646-17620-302 00646-17620-303 00646-17620-304

Transcript of 00602-17620-3xx TRD 1mz Supercharger Manual

Page 1: 00602-17620-3xx TRD 1mz Supercharger Manual

Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

Supercharger Kit Part Numbers:00646-17620-30100646-17620-30200646-17620-30300646-17620-304

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

Section 1: Installation PreparationKit Contents

Qty Description Connection or Installation Location Page Part Number1 Supercharger/Manifold Assembly - Camry/Solara Main Assembly - Bolts directly to OE Manifold. 11 00646-17620-3071 Supercharger Belt - Camry/Solara Replaces OE Alternator Belt. 15 00646-17620-3301 Assembly, Idler Plate and Pulley - Camry/Solara Installed on front of engine. 14 00646-17620-3201 Convoluted EGR Tube - 5 Speed Replaces OE EGR Tube. 10 17620-355or Convoluted EGR Tube - Automatic Replaces OE EGR Tube. 10 17620-3601 Kit, Literature1 Manual, 3.0 Installation1 Warranty Card Fill out and send in to TRD.1 Warranty Certificate Keep in glove compartment.2 Decal, Kazuma Place as desired. Usually placed on OE Timing Belt Cover.1 EO Sticker Place underneath hood. 171 Belt Routing Sticker Place underneath hood. 171 Premium Fuel Sticker Place one on or near fuel gauge, the other inside fuel filler door. 17

Supercharger Brochure, Catalogs, Promo. Matl.1 Idler Plate Installation Kit2 Bolt, Allen Head - 10mm x 1.25mm x 30mm Attaches Idler Plate to engine. 141 Bolt, Counter Sunk - 10mm x 1.25mm x 100mm Alternator Pivot Bolt - Installed through Idler Plate and Alternator Pivot Bolt Spacer. 141 Spacer, Alternator Pivot Bolt Installed between Idler Plate and Alternator Pivot Mount. 141 Bracket, Drive Plate Attaches Idler Plate to engine. 141 Bolt, Counter Sunk - 8mm x 1.25mm x 20mm Used to attach Drive Plate Bracket to engine. 141 Washer, Flat - 8mm Used with 8mm x 1.25mm x 20mm Counter Sunk Bolts. 141 Nut, Nylock - 8mm x 1.25mm Used with 8mm x 1.25mm x 20mm Counter Sunk Bolts. 141 Bolt, Hex Head - 10mm x 1.25mm x 100mm Attaches Engine Moving Control Rod through Idler Plate and Gooved Pully. 161 Washer, Flat - 10mm Used with 10mm x 1.25mm x 100mm Hex Head Bolt. 161 Nut, Nylock - 10mm x 1.25mm Used with 10mm x 1.25mm x 100mm Hex Head Bolt. 161 Hose, Connector and Hardware Kit2 Stud, 8mm x 1.25mm x 50mm Attach to bottom two holes on Supercharger Intake Plenum to mount Throttle Body Assembly. 131 Vacuum Hose - 5/16" x 13" long Connects PCV valve to Supercharger Assembly. 10, 111 Vacuum Hose - 3mm x 8" long Connects PWM VSV to Vacuum Control Tank (VCT). 13, 18, 192 Vacuum Hose - 3mm x 15" long One hose connects Vacuum Control Tank (VCT) to EGR valve and the other hose connects

Vacuum Control Valve (VCV) to Supercharger Assembly. 13, 18, 193 Hose Clips, Black Plastic Retains vacuum hoses in their proper places. 13, 18, 191 Valve, IAC, Check Installed near IAC valve. 72 Bolt, Hex Head - 6mm x 1.0mm x 18mm Attaches EGR valve to engine. 122 Washer, Flat - 6mm Used with 6mm x 1.0mm x 18mm EGR bolts. 122 Vacuum Caps Used to cap off Acoustic Control Induction System (ACIS) VSV and associated pipe. 13, 18, 191 90 degree elbow Attaches vacuum hose to EGR valve. 13, 18, 191 Barb, 1/8" 1 each placed in 90 degree elbow. 13, 18, 193 Large Zip Tie Used to tie engine main wiring harness to low pressure refrigerant line. 106 Medium Zip Tie 1 used to tie PVC hose to engine, 1 used to tie unused vacuum tank hoses to engine harness,

2 used to tie ground straps and coolant recovery hose to Engine Moving Control Rod and 2 used to tie Vacuum Control Tank (VCT) to front of engine. 10, 13, 17, 18, 19

Miscellaneous1 Strut Tower Brace Used only with Kits 00646-17620-301 and 00646-17620-302 17

Service Parts - not included as spare in kit.2 per assy. Pulley and Bearing Assembly, Smooth For use as service items only. 00602-17620-0192 per assy. Pulley and Bearing Assembly, Grooved For use as service items only. 00646-17620-325

Tools RecommendedBasic Tools Basic Metric Socket, Allen & Open-End Wrench Sets

1/2" Wide Masking Tape for Labeling Hardware and PartsA Clean Work BenchA Parts TrayRags or Shop Towels

Safety Tools Safety Goggles

Special Tools Tensionometer (available from Kent-Moore, 1-800-345-2233) See figure 48Toyota Repair Manual (available from Toyota, 1-800-622-2033)

Accessories TRD shift control unit, part # 00646-17620-375(Automatic transmission vehicles only)

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

Figure 1

Figure 2

Figure 3

Section 2: Removal Procedure

A. Preparation for Removal of Stock Air Intake Chamber (Manifold)

• Before you begin, TRD recommends that you thoroughly clean the engine and engine compartment. If you don’t, grease buildup on parts could become dislodged during the procedure and fallinto the engine.

• Make sure the engine has cooled fully before you begin.

• To help you later, you might want to draw diagrams of your engine’s vacuum hose routing before you disconnect anything. However, some of the vacuum connections on your stock air intakechamber may not be the same as those on the supercharger. To ensure the proper hose connections, please refer to the diagrams inthe back of this book.

• The TRD supercharger kit has been designed to reuse most of thestock nuts and bolts. Therefore, as you remove them, keep them with their components or label them for location. This will assure a faster, easier installation.

B. Removal of Stock Intake Chamber

1. Disconnect the ground cable from the battery.

2. For Solara models, remove the OEM strut tower brace.

3. Remove the V-bank cover (figure 1).

4. Unplug the two engine-to-body ground wires(see arrow A, figure 2).

5. Remove the coolant recovery hose from the water outlet housing (see arrow B, figure 2).

6. Loosen the clamps from the throttle body air intake tube(see arrows A, figure 3).

7. Remove the vent hose from the cam cover(see arrow B, figure 3).

8. Remove the throttle body air intake tube from the engine.

A

B

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

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TIP: The gravel guard consists of two pieces but it’s much easier to install if you remove it as a one-piece assembly.

9. Unplug the connectors from the throttle position sensor (A) and the IAC (Idle Air Control) valve (B) (see arrows, figure 4).

10. Unplug the connectors from the EGR position sensor (A)and the EGR gas temperature sensor (B) on the EGR valve(see arrows, figure 5).

11. Remove the brake servo vacuum hose from the air intakechamber (see arrow, figure 6).

Figure 4

Figure 5

Figure 6

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

12. Remove the two bolts and the two nuts from the throttle body (see arrows, figure 7).

13. Remove the throttle body and set it aside. Do not disconnect any cables.

14. Remove and save the throttle body’s metal gasket. It will be reused.If gasket needs replacement, use Toyota part # 22271-20010.

15. Disconnect the evaporative (EVAP) canister vacuum hose from the air intake chamber (see arrow, figure 8).

16. Remove the upper bolt holding the chamber stay to the back of the air intake chamber (driver’s side) and move the stay enough to gain access to the nuts holding the EGR valve pipe (see arrows, figure 9).

17. Remove the four nuts from the EGR pipe (see arrow, figure 9)and remove the pipe and the two gaskets. The gaskets will be reused in the installation procedure. If the gaskets need to be replaced, use Toyota part # 25627-20010.

Figure 7

Figure 8

Figure 9

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

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18. Remove the three nuts from the EGR valve and remove the valve with the gasket from the air intake chamber (see arrows,figure 10). The gasket will be reused in the installation procedure. If the gasket needs to be replaced, use Toyota part # 25627-20010.

19. Remove the Vacuum Switching Valve (VSV)-to-EGR hose from the EGR valve (see arrow, figure 11).

20. Remove the two ground straps from the air intake chamber(see arrow, figure 12).

Figure 10

Figure 11

Figure 12

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

21. Remove the Acoustic Control Induction System (ACIS) vacuum hose from the VSV (see arrow, figure 13).

22. Remove the nut holding the power steering line to the passenger’s-side engine hanger and pull it back enough to access the engine hanger bolt (see arrow, figure 14).

23. Remove the bolt holding the engine hanger to the passenger’s side of the air intake chamber (figure 14).

24. Remove the ground strap from the back of the air intake chamber (see arrow, figure l5).

25. Unclip the spark plug wire loom and set aside. Figure 13

Figure 14

Figure 15

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

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26. Remove the two VSV rack nuts and lay the rack to one side.

27. Disconnect the two vacuum hoses from the air intake chamber (see arrows, figure 16). One goes to the vacuum tank,the other to the Vacuum Control Valve (VCV).

28. Remove the two Allen bolts and the two nuts from the air intake chamber (see arrows, figure 17).

29. Lift up on the air intake chamber and tilt it to the rear, remove the PCV hose from the bottom (see arrow, figure 18)then remove the air intake chamber from the vehicle.

Figure 16

Figure 17

Figure 18

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

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30. With the EGR valve off the vehicle, remove the EVAP canister hose bracket from the valve (see arrow, figure 19). The bracket won’t be used in the installation procedure.

31. To keep out debris, cover the intake ports with a clean shop cloth.

32. Cut the IAC hose and insert TRD’s one-way valve with the mark closest to the throttle body (see arrow, figure 20).

CAUTION: Make sure you don’t cut the fuel line or water bypass hoses instead.

Figure 19

Figure 20

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

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33. Remove the three bolts from the passenger’s-side engine mount stay (see arrows, figure 21). For manual transmission vehicles, remove the second engine mounting stay (see arrows, figure 22). Neither stay will be reused with the supercharger. Bolt (A) (Figure 21) will be reused in the installation procedure.

34. Remove the center bolt from the engine moving control rod(see arrow, figure 23). This bolt will not be reused.

35. Remove the two bolts holding the #2 engine mounting bracket from the engine and remove the bracket (figure 24). Bolts and bracket will not be reused.

Figure 23

Figure 22

Figure 24

Figure 21

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

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36. Slide the relay box from its bracket to provide access to the alternator adjuster bolt (figure 25).

37. Loosen the alternator pivot bolt, the adjusting lock bolt and adjusting bolt (see arrows, figure 26) and remove thealternator belt. The belt will not be reused with the supercharger.

38. Remove the stock alternator pivot bolt, nut and alternator support bracket. Reinstall the nut on the stud (see arrows, figure 27). The bracket and OE pivot bolt will not be reused.

Figure 26

Figure 25

Figure 27

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

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39. Using the original equipment (OE) EGR metal gaskets and nuts, install the TRD-supplied convoluted EGR pipe to the two lower studs on the EGR cooler and for now, leave the nutsloose so that the tube can be easily maneuvered (figure 28).

40. Unclip the main engine wiring harness and using the large TRD-supplied zip ties, attach the harness to the low-pressure refrigerant line as illustrated in (figure 29). Trim off any excess zip tie material.

41. Install the 5/16" x 13" TRD-supplied vacuum hose to the PCV valve and using one medium TRD-supplied zip tie, attach the hose to the injector wiring loom(see arrow, figure 30).

Figure 29

Figure 30

Figure 28

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

Section 3: Installation Procedure

A. Installation of TRD Supercharger Assembly

1. Position the supercharger assembly just above the engine.

2. Install the PCV valve hose to the supercharger assembly(see arrow, figure 31) and maneuver the supercharger onto the engine. Install the OE bolts and nuts previously removed in section 2, part B, step 28 and hand tighten for now.

3. Remove the bolt from the supercharger’s drive housing as shown in (figure 32), attach the two ground wires, reinstall the bolt and torque to 20 lbs. ft.

4. Attach the third ground wire to the back of the supercharger assembly and torque to 12 lbs. ft. (see arrow A, figure 33).

5. Bolt the passenger’s-side engine hanger to the back of the supercharger assembly and hand tighten for now(see arrow B, figure 33).

Figure 31

Figure 32

Figure 33

AB

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

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6. From the driver’s side, remove the locknut and washer from the back of the supercharger assembly. Install the chamber stay over the stud and collar using the washer and locknut. Hand tighten for now (see arrow, figure 34).

7. Torque the supercharger bolts and nuts to 32 lbs. ft. Torque thepassenger’s-side engine hanger to 29 lbs. ft. and reinstall the power steering line onto the stud using the OE nut and tighten until snug (69 lbs. in.). Torque the driver’s-side chamber stay to 14 lbs. ft.

8. Position the EGR valve and its gasket on the supercharger assembly, install the two TRD-supplied 6mm x 18mm bolts and 6mm washers and hand tighten for now (figure 35). The bottom bolt hole on the EGR valve is not used withthe supercharger.

9. Position the gasket and TRD-supplied convoluted EGR pipe onto the EGR valve and tighten. Torque all four EGR pipe nuts and two EGR valve bolts to 9 lbs. ft.

10. Install the brake servo vacuum hose to the vacuum fitting on the air intake chamber (see arrow, figure 36).

Figure 35

Figure 34

Figure 36

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

11. Install the two TRD-supplied 8mm x 50mm studs into thetwo bottom holes on the supercharger intake plenum.

Note: When installing the 8mm x 50mm studs, make sure the short threaded end of each stud is installed into thesupercharger assembly.

Install the throttle body and gasket. Install the EGR gastemperature bracket, two OE nuts and two OE upper bolts andtorque each to 14 lbs. ft. (see arrows, figure 37).

12. Plug in the connectors to the IAC valve, the throttle position sensor, the EGR gas temperature sensor and the EGR position sensor (refer to section 2, part B, steps 9 and 10).

13. Install the VSV rack with the original nuts and tightenuntil snug.

14. Re-attach the spark plug wire loom.

15. Cover the two VSV vacuum ports with the TRD-supplied caps (see arrows, figure 38) and using one TRD-supplied medium zip tie, tie the two hoses (A & B) out of the way. They are no longer needed. Refer to the diagrams in the back of this book.

16. Install the TRD-supplied 3mm x 8" and the two 3mm x 15"vacuum hoses according to the diagrams in the back of thisbook. Reinstall the EVAP canister vacuum hose to the airintake chamber.

Note: When installing the 90o elbow to the EGR valve, asmall portion will have to be trimmed in order for theelbow to fit properly.

17. Remove the two top grooved pulleys from the idler plate.Note the position of the collars for reinstallation(see arrow, figure 39).

Figure 39

Figure 37

Figure 38

A B&

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

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18. Install the TRD idler pulley plate using the TRD-supplied10mm x 30mm Allen-head bolts and leave the bolts loose for now (see arrows, figure 40).

19. Install the TRD-supplied 10mm x 100mm flat-headalternator pivot bolt through the idler plate & the TRD-supplied spacer. Hand tighten to the alternator mount. (see arrow, figure 41).

20. Install the TRD-supplied plate support bracket with the TRD-supplied 8mm x 20mm flat-head bolt, 8mm washer and8mm locknut. Mount the bracket to the water outlet housingusing bolt (A) from Section 2, Part B, Step 33.(see arrows, figure 42) Hand tighten for now.

Figure 41

Figure 42

Figure 40

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

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21. Tighten all bolts according to the sequence and torque specs shown in figure 43.

22. Install the TRD-supplied supercharger belt according tofigures 44 and 45.

23. Install the spacer collar to the inside of the idler pulley(see arrow, figure 46).

IMPORTANT: In order for the TRD-supplied supercharger belt to line up properly, the spacer collar placed onto each of the two grooved idler pulley shafts must face the engine.

Figure 45Figure 43

Figure 44

Figure 46

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

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24. Install the two grooved idler pulleys and the engine moving control rod using the TRD-supplied bolts and locknuts(figure 47) and torque to 20 lbs. ft.

Note: Use the TRD-supplied flanged 10mm x 100mm bolt, 10mm washer and 10mm locknut with the enginemoving control rod. Install this bolt and pulley first.

25. Using the Kent-Moore tensionometer, tension the beltaccording to new-belt specs—120 lbs. (figure 48).

26. Torque the alternator adjuster lock bolt to 13 lbs. ft.

27. Install the relay in its bracket. (Refer to figure 25)

28. Plug in the two engine-to-body ground wires(see arrows, figure 49).

Figure 48

Figure 47

Figure 49

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

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29. Connect the coolant recovery hose to the water outlet housingand secure the hose and the ground wires to the engine movingrod with the two TRD-supplied medium zip ties (see arrow, figure 50).

30. Install the air intake tube to the throttle body and tighten its clamps. Install the vent hose to the cam cover.

31. Connect the ground cable to the battery, run the engine for about 15 minutes and recheck the belt tension. It should fall between 70 and 90 lbs.

32. For Solara models, install the TRD-supplied strut tower braceand torque the nuts to 59 lbs. ft.

33. Re-check all vacuum lines & connections. Re-install V-bank cover.

34. Apply the premium-fuel stickers to the fuel gauge and fuel filler door.

35. Apply a TRD belt routing sticker and the Executive Order (EO) label to the underside of the hood. The EO will alert state smog inspectors that the TRD supercharger has been certified emissions legal in all 50 states.

Figure 50

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

Figure A

Notes:

Notes:

1997Avalon, Camry

1998Camry

Year

Model

Year

Model

Figure B1998Avalon

Year

Model

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

Notes:

Notes:

Figure D1999-2000Camry, Solara

Year

Model

Figure C1999Avalon

Year

Model

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Installation Instructionsfor 3.0-liter V6 Supercharger Kit

1997-2000 Camry,1999-2000 Solara,1997-1999 Avalon

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Symptom Possible Causes Corrective Action

Idles rough, “pings” Lean condition— Check vacuum line connections for leaks and cracked ends.(Trouble Code PO171—Lean Code) vacuum leak

Review factory service manual for proper factory vacuum routing.

Review instructions for proper vacuum line routing.

Check installation of the TRD throttle body gasket. If gasket is installedimproperly, a vacuum leak will occur.

Recheck torque on throttle body bolts.

Leak at manifold gasket.

Recheck torque on intake manifold bolts.

Pings during acceleration Low octane fuel Fill tank with premium fuel. BE SURE TO USE 92 OR HIGHER OCTANE FUEL.

Computer has yet to Drive several hundred miles in different driving modesadjust to supercharger (Not all steady-state highway cruising, for example).

Insufficient fuel delivery Fuel filter old—replace. Follow factory diagnosis and replacement procedures.

Fuel pressure low. Follow factory diagnosis and replacement procedures.

Injector(s) clogged. Follow factory repair/replacement procedures.

Low boost Belt slipping Recheck belt tension using tensionometer.

Check condition of belt—oily, worn, high mileage.

Air filter dirty Check/replace air filter. A dirty filter restricts the air intake. TRD dynotests have shown that the TRD air filter is among the best on the market for flow and filtering characteristics.

Throttle not fully opened Recheck and adjust the throttle cable and transmission cable. Be sure thatfull depression on the gas pedal achieves full throttle opening at the throttle body.

Makes a moderately loud noise Normal supercharger No remedy. Superchargers are an air pump and the pumping action is under full throttle—intake noise sound impossible without some noise. Call TRD for further diagnosis.

Rattling at idle—goes away Normal supercharger Slight rattle at idle is normal, but only if noise sharply decreases at at just above idle sound 400 - 500 rpm above idle. Call TRD for further diagnosis.

Rattling above idle—gets louder Drive housing bearing Call TRD for further diagnosis.with higher rpm or louder with wear or backlashmore boost pressure

Idler pulley bearing Diagnose by removing belt from supercharger and running engine for less than wear or excessive freeplay 30 seconds. If noise continues, source of problem is not within supercharger.

Belt too loose Check and re-tension belt as necessary. BE SURE TO USE A TENSIONOMETER.

Supercharger belt jumps Misaligned pulley/idler Check to be sure that the collars placed onto the pulley shafts face towards the engine.across pulley grooves

Damaged pulleys Be sure that the pulleys all run true—no eccentricity.

Loose pulleys Check to be sure that the crankshaft pulley is properly tightened. Re-tightento specifications given, follow the procedures in the factory manual.

Supercharger belt leaves grey/black Normal break-in residue No corrective action. Belt should be fully broken in after 2000 miles.powder on drive housing and other areas

Supercharger appears to leak oil Front seal not fully No immediate corrective action. Seal should be fully mated to pulley afterfrom drive housing broken in 2000 miles. If leaking continues, contact TRD.

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