Toyota TRD 3.4 5VZFE Supercharger Install Instructions

7/15/2019 Toyota TRD 3.4 5VZFE Supercharger Install Instructions

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TRD 3.4-l iter V6Supercharger KitInstallation Instructions

Supercharger Kit Part Number: PTR29-8902

1996 - 2002 4Runner

1997 - 1998 T100

1997 - 2004 Tacoma

2000 - 2003 Tundra



IMPORTANT WARRANTY INFORMATION

Dealers – Technic ians:Fa i lu r e to com p le tely and p rope r ly f i l l ou t and m a i l in you r cus tom er ’s War ran ty Reg ist r a t ion Card m ay resu l t in possib le r educ t ion o rcom p le te den ia l o f f u tu re war ran ty c la im s.

Customer installed units:Fa i lu re to comp l e te ly and p rope rly f i l l ou t and m a i l in you r War ran ty Reg ist r a t ion Card m ay resu l t in possib le r educ t ion o r com p leteden i a l o f f u tu re war ran ty c la im s.



1996 – 2002 4Runner 1997 – 1998 T-1001997 – 2004 Tacoma2000 – 2003 Tundra

Qty Description Connection or Installation Location1 Supercharger / Manifold Assembly Main Assembly – Bolts directly to Factory Manifold1 Supercharger Belt Replaces Factory Alternator Belt1 Assembly, Dynamic Tensioner 1 Assembly, Tensioner Plate and Pulley Installed on front of engine 1 Dynamic Tensioner Plate Installed on front of engine1 Assembly, Tensioner Plate Ins tal lat ion Hardware 1 Bolt, 10 X 1.25 X 73mm Flat Head Bolt hole A1 Bolt, 10 X 1.25 X 130mm Flat Head Bolt hole B1 Washer, 10mm Flat Bolt Hole C1 Wiring Loom Relocation Bracket Installed on front of engine1 Dipstick Relocation Bracket Installed on front of engine1 6 X 1.0 X 12mm Bolt, Flange Head Dipstick Relocation Bracket

1 Kit, Literature 1 3.4L Installation Manual, Rev 8/10/081 Gasket, 3.4 S/C Between Factory Throttle Body and TRD Supercharger1 EO Sticker Place underneath Hood1 Warranty Card Fill out and return to TRD 1 Warranty Certificate Place in glove compartment1 Mirror Hanger, S/C Noise Warning Makes customer aware of Roots-type supercharger whine2 Sticker, TRD Logo Place as desired on external surfaces of vehicle3 Decal, Supercharger Place as desired1 Template for cutting Front Cover Use to modify Factory Timing Belt Cover1 Belt Routing Sticker Under Hood2 Premium Fuel; Sticker Place 1 on or near fuel gauge and 1 inside of fuel filler door3 Set, TRD S/C Emblems Place as desired

1 Hose, Connector and Hardware Kit

1 1/8” Vacuum Plug 2001 and newer Tacoma only w/Drive by wire throttle body1 3/8” Vacuum Plug Intake Silencer Plug1 Vacuum Hose – ½” X 34” long Connects Air Tube to Cam cover1 Vacuum Hose – 1/8” X 14” long Connects Vacuum Throttle opener to Intake Manifold1 Wide Band Spring Clamp, Red Secures Breather Hose at the 12mm Valve Cover Barb4 Zip Tie, 3/16” X 7” Retains Evaporative Canister Hose to Throttle Cable1 Vacuum Adaptor Tee- 4WD only See Hose Routing Schematic Figure B1 Valve, IAC Check Installed near IAC Valve1 Spacer, Manifold Support Bracket Installed between manifold & factory support bracket, driver side1 Bolt, 8 X 1.25 X 35mm Flange Head Secure factory support bracket thru spacer to S/C Manifold1 Bolt, 8 X 1.25 X 170mm Flange Head Installed thru top of S/C to Factory Manifold1 Bracket, Accelerator & Transmission Cable Used on all models except 4WD M/T Tacoma1 Bracket, Accelerator Cable Used on 4WD M/T Tacoma only1 Bracket, Throttle Cable 2001 & newer 4Runner only w/Drive by Wire Throttle Body2 Bolt, 6 X 1.0 X 12mm Flange Head Used to attach Throttle Cable Brackets to S/C Manifold

Tools Recommended Safety Tools Safety goggles

Basic Tools Basic Metric Socket, Allen & Wrenches Special Tools LocTite®P/N 243

Pencil & Paper for drawing schematics of Cable Routing 14mm Angles Flat Ratchet, Power Steering½” Masking tape for labeling hardware, parts, etc. Adjuster bolt2” wide masking tape for covering intake manifold Scribe for marking Timing Belt CoverA clean Work Bench Coping saw for cutting Timing Belt CoverA Parts Tray Toyota Repair Manual (1-800-622-2033)Rags and or Shop Towels



Installation Instructionsfor 3.4-liter V6 Supercharger Kit

Figure 1

Figure 2

Section 2: Removal Procedure

A. Preparation for Removal of StockIntake Manifol d

• Befo re you beg in , TRD recomm ends tha t you th o rough ly c leanthe eng in e and eng in e com par tm en t . I f you don ’ t , g rease bu i l dupon pa r t s cou ld becom e d islodged du r in g the p rocedure an d fa l li n to the eng in e .

• Make sure the engine has cooled fu l ly before you begin.

• T o h e l p y o u l a t er , w e su g g est yo u d r a w d i a g r am s o f yo u r e n g i n e’ scab le r ou t in g befo re you d isconnec tany th in g . You can do the sam efo r the vacuum hoses; however , som e o f t he vacuu m connec t ionson you r stock m an i fo ld m ay no t be the sam e as those on th esup ercharger . To ensure the proper h ose conn ect ions, refer to thed i a g r a m s i n t h e b a ck o f t h i s m a n u a l .

• Th e TRD supercharger k i t has been designed to reuse m ost o fthe stock nu ts an d bol ts. Therefore, as you r em ove them , keepthem w i th the i r com ponen ts o r label t hem fo r loca t ion . Th is w i l lassur e a faster , easier in sta l la t io n.

B. Removal of Stock Intake Manifold (fi gure 1)

1 . D i sc o n n e ct t h e b a t ter y g r ou n d c a bl e .

2 . W i th t a p e o r a per m a n en t m a r k er , m a r k th e forward edge ofthe power stee r ing an d th e a i r cond i t ion i ng com presso r d r ive be l t s( f igure 2) . Th i s w i l l ensu re tha t t h e bel t s w i l l be r e tu rned tothe i r o r ig in a l posi t ion s and tha t t h ey w i l l r o ta te in th e sam ed i r ec tion . I f you r eve rse the d i r ec tion o f r o ta t ion , i t m ay causethe bel ts to f ray.



Install ation Instructionsfor 3.4-l iter V6 Supercharger Kit

3 . I f equ ipped , r em ove the g ravel gu a rd f r om benea th th e r ad ia to r

( f igure 3) . Th is w i l l g i ve you access to the A/C bel t ad ju ster.

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

4. Loosen the p inch nut in the center o f the A/C compressor be l tpu l l ey and loosen the ad jus ter bo l t enou gh to loosen the be l t(see arro w, f igure 4) .

5 . Usin g the ang led f la t r a t che t , loosen the p inch nu t and ad ju sterbo l t f o r t he power stee r ing pu m p.

6. Rem ove the two bel ts.

7 . Loosen the a l terna to r p ivo t bo l t ( t op ) , p inch n u t and ad ju st ing bo l tand r em ove the a l te rna to r bel t . Du r i ng th e ins ta l la t ion p rocedure , i tw i l l be rep laced with a bel t suppl ied with the supercharger .

8 . Loosen the a i r in take tube c lam ps at t he th r o t t le body and d iscon -nect the M ass Air Flow Sensor p lu g.

CAUTION: The air sensor (see pointer, f i gure 5) is fragile so be careful when working around it.

Figure 3

Figure 4

Figure 5




9 . Rem ove any conn ect ions f r om the a i r in take tube and rem ove the

t u b e ( f i gure 6) .

10 . Som e t r ucks a re equ ipped w i th on e o r two Vacuu m Sw i t chedValve ( VSV) assem bl i es. To locate you rs, consul t th e appropr ia ted iag ram s on pages 20 through 23 . I f t he va lve i s m oun ted onthe rear of the engine, i t should be re located to the f i rewal l w i ththe bracket suppl ied.

11 . No te the tens ion an d ad ju stm en t o f t he th ro t t le cable and th et r ansmi ssion th ro t t le -p ressu re ( k ickdown ) cab le ( i f equ ippedw i th an au tom at ic t r ansmi ssion ) . You w i l l need to r e- c rea tethese adjustments dur ing the assembly procedure. To help youremem ber , look fo r t he sm a l l m e ta l bead ( th e stake stopper , au to -

m a t i c tr a n sm i ssi o n o n l y ) o n t h e k i c k d o w n c a bl e (see ar ro w,figure 7) . I f the cable is proper ly adju sted, the bead shou ld bef lush with the end of the cable ’s rubber sheath (see arr ow, fig-ure 8) .

Figure 6

Figure 7

Figure 8



Figure 10

A

B

Install ation Instructionsfor 3.4-liter V6 Supercharger Kit

TIP: If your vehicle is equipped with cruise control, do not remove the cruise cable from the throttle body. If you do,you will have to readjust it later.

12. Loosen bu t don’ t r emove t he cab le nu ts ( f igure 9) .S l ide the cables f rom their br ackets and r em ove the cable endsfrom the throt t l e-body levers.

13 . Unp lu g the th ro t t le -posi t ion senso r conn ecto r (A ) and th e IAC( I d le Ai r Con t ro l ) va lve conn ecto r (B ) (see ar r ows, f igure 10and diagram on page 23) .

Figure 9




14 . Rem ove vacuum l in es f r om the th ro t t le body bu t don’ t r emove

the two coolant hoses (figure 11) .

TIP: The coolant hoses have clamps (see arr ows, fi gure 12),the vacuum hoses do not.

15. Remove the throt t lebody with a t tached coo lan t h oses and c ru isecontr o l cabl e ( i f equ ipped) and set to the passenger ’ s s ide ( f igure12) .

16. At the dr i ver ’s s ide of th e eng in e, rem ove the d iagn ost ic p lugf r o m i t s m o u n t i n g b r a ck e t (upper arrow, f igure 13) and seti t a si d e. R em o v e t h e b ol t a n d b r a c k e t t h a t h o l d st h e d i a g n o st i cc o n n e c t o r t o t h e s t o c k m a n i f o l d a n d s a ve f or r e assem b l y .

Remove the g round w i r e and m ove i t t o one side ( lower ar r ow,f igure 13) .

17. Rem ove the vacuum hoses for th e power brak e, PCV and EVAPf rom the i r t ubes on the upper man i fo ld .

Figure 11

Figure 12

Figure 13



Install ation Instructionsfor 3.4-l iter V6 Supercharger Kit

Figure 14

Figure 15

Figure 16

18 . A p re -2000 Tacom a o r T-100 m ay be equ ipped w i th an EGR va lve .

To be sur e, look for th is tube (see arro w, f igure 14) o n t h ed rver ’s - side exh aus t man i fo ld . Remove the va lve acco rd ing to theprcedure on page 14.

19 . Rem ove the bo l t ho ld in g the man i fo ld to the in take cham ber stay(see arro w, f igure 30) . Save the bol t .

20 . Rem ove the nu ts and bo l t s f r om the upper ha l f o f t he in take man i -fo ld an d set i t aside ( f igure 15) .

21 . Rem ove the 2 bo l t s and d i sconnec t t he fue l - r e tu rn l in e b racke t(but don’t disconnect the fuel hose) f r om the d r ive r ’ s sideo f t he lower m an i fo l d and remove the bo l t f r om the w i r e - loom

bracket .

22 . Rem ove the bo l t s and n u ts fr om the lower m an i fo ld .

TIP: The nuts at the far ends of the manifold will be reused during installation. To avoid losing them, pick them up with a magnet.

23 . Rem ove the lower m an i fo ld ( f igure 16) and save the factorynu ts, washers an d two shor t bo l ts, as they wi l l be reused.

24. In spect the gasket . I f i t is in good shape, reuse i t ; i f n ot , rep lace i tw i th a new one (pa r t# 17176-62040) .

NOTE: The gasket between the surge tank and the manifold (figure 15) is interchangeable for use as the supercharger’s intake manifold gasket (see section B – 2, page 11).




25. Tape over or cover th e eng in e ma ni fo ld por ts to keep out debr is

( f igure 17) .

26 . Usin g the tem p la te supp l i ed and a sc r ibe o r m arke r , mark the topo f t he tim in g bel t cover a roun d the tem p la te ( f igure 18) .

27 . Move any w i r es ou t o f t h e way and w i th a cop ing saw b lade o rf lex ib le saw , cu t a lon g the scr ibe m ark ( f igure 19) and d isca rdthe cu t - ou t p iece. Th i s cu taway w i l l p rov ide the c lea rance fo r t hed r ive hous ing o f t he supercha rge r .

Figure 17

Figure 18

Figure 19



Figure 21

Installation Instructionsfor 3.4-l iter V6 Supercharger Kit

Figure 20

Figure 22

A

B

Hole C

28. At tach th e p last ic w i re loom s to the cut edge of the f ront cover

( f igure 20) . Th e ign i t ion w i r es w i l l go benea th th e supercha rge rd r ive hou sin g .

Section 3: Installati on Procedure

A. Install ation of TRD Dynamic BeltTensioner Assembly

1 . Remove d ipst i ck an d d ips t i ck tube .

2 . Unc l ip the w i r e loom f r om the facto r y b racke t and ins ta l l t he TRD-supp l i ed w i r e loom re loca tion b racke t (see arro w, f igure 21) .

Use the ex is t ing n u t on the wa ter pum p hou sin g ’s upper s tud .To rque to fac to r y speci f i ca t ions and c l ip th e w i r e loom to the backo f t he TRD b racke t.

3 . I n sta l l t h e bel t t ens ione r p la te usin g the TRD f la t h ead bo l t( 1 0 x 1 .2 5 x m m ) i n L o ca t i on A ( f igure 22) , do no tfu l l y t igh ten ye t.

NOTE: If the vehicle has been in use, the holes (Arrows A &B in figure 22) may need to be cleaned out (i.e. tap).

4 . Usin g the TRDsupp l ied bo l t ( 10 x 1 .25 x ) ( f igure 22) ,a l ign the lower bel t t ension e r mou n t in g bo l t ho le to Loca t ion B .

NOTE: TRD recommends the use of a thread locking liquid (such as Loctite 262) on the 10 x 1.25 x mm & 10 x 1.25 x

mm bolts in Locations A & B.

5 . Torque the bo l t i n Loca t ion A to 25 f t . / lbs .

130

130

73

73




Figure 24

Figure 23

6 . Rem ove the bo l t in Loca t ion B . Se t the a l te rna to r t o m id -po in t

ad jus tm en t on th e ad justab le b racke t (see figure 23) . T o r q u ethe p ivo t bo l t ( t op ) and p in ch nu t ( a r r ow) to facto r y spec i f i ca t ion .

7. Place th e dynam ic ten sion er onto the m oun ting plate with th e beltbehind the pul l ey (figure 24) .

NOTE: Align the stud on backside of tensioner to small hole “C” in belt tensioner plate (figure 22).

8 . Ins ta l l t he hex head bo l t ( r em oved in Step 5 ) t h rough the tens ione rin to the m ou nt i ng p l a te and torque to 40 f t ./ lbs.




Figure 25

Figure 26

Figure 27

B. Installati on of TRD Supercharger andManifold Assembly

1 . ( Skip this step for 2001 and newer 4Runner) Cut th e ho selead ing to th e IAC va lve conn ecto r a t t h e loca t ion shown , an d in se r tthe k i t ’ s one -way valve in to the st r a igh t pa r t o f t he h ose . The b lack endof the va lve (see arrow, figure 25 and diagram on page 23)is c losest to th e thr ot t le body.

IMPORTANT: The IAC hose and the coolant hoses are similar in size.Don’t cut the wrong one. The coolant hoses have clamps, the IAC hose does not.

2 . Rem ove the tape f r om the in take m an i fo l d and re ins tal l t h estock gasket.

3 . Lower the supercha rge r and m an i fo l d in to p lace m ak in g su ret h er e a r e n o h o ses o r w i r e s i n t h ew a y. T h e i g n i t i on w i r es sh o u l d b erouted beneath the supercharger ’s dr ive housing (see ar ro w,f igure 26) .

4 . When th e assemb l y si t s f la t on th e eng in e , pu t t h e stock m an i fo ldbrace (dr iver ’s s ide) bo l t and TRD spacer in f i rst (see arrow, f i gure27) and th en in sta l l t h e stock nu ts on th e studs a t each end o f t h em a n i f o l d a n d h a n d t i g h t en .

5 . I n st a l l t h e T R D - su p p l i e d l o n g m a n i f o l d b o l t ( 8 x 1 .2 5 x 1 7 0 m m )th rou gh th e supercha rge r to the stock m an i fo ld fo l lowed by the twostock bol ts. Al ternat ing f rom one side to the other , torque the bol ts andtwo nu ts to the specs p rovided in the Toyo ta Repai r M anu a l .

NOTE: In step #1 above, the valve

in your kit may not have a black

end. You can determine the flow

direction by gently blowing thruit. The valve needs to be installed

so that the flow goes into the

engine.

Use M x mm Bo t



Install ation Instructionsfor 3.4-li ter V6 Supercharger Kit

Figure 28

Supercharger

Pulley

TensionerPulley

AlternatorPulley

WaterPumpPulley

Figure 30

6. Place the dr ive bel t over the water pum p pul l ey, the crank shaf t

pu l l ey and th e a l te rna to r pu l l ey (figure 28) . Ma ke sure the belt ison th e correct sides of and pro perly seated i n th e grooves of eachpul ley.

7 . To assis t in be l t in sta l la t ion , us ing a 3 / 8 " l ong h and le r a tche t(fi gure 29) , pu l l down in d irect ion of ar r ow to provide slack onbel t.

8 . Insta l l the power steer ing and A/C bel ts accord ing to the marks youm ade befo re r em ova l ( see section 2 , f igur e 2, page 2) .

9 . In sta l l th e TRD-suppl ied d ipst ick re locat ion bracket (see arr ow, fi g-ure 30) u t i l i z in g the fac to r y bol t . Re ins ta l l t h e facto r y d ipst i ck an d

a t tach i t t o new b racke t usin g the TRD-supp l i ed bo l t ( 6m m x 1 .0 x12m m ) To rque bo th bo l t s to 10 f t ./ l bs.

NOTE: Be sure to maintain proper dipstick tube seal at oil pan.Check rubber grommet at end of dipstick tube for engagement.

Figure 29

.




Figure 31

Figure 32

Figure 33

B

A

B

B

A

C. Throttle Body and Air Tube Install ation

NOTE: If your vehicle has an EGR system, see Sec. 4 on Page 18.

1. Using the gasket , , in sta l l theth ro t t le body on to the supercha rge r ’s man i fo ld .

IMPORTANT: Do not reuse the OE metal gasket (A, fi gure 31) on the throttle body. It will reduce boost output by 1 1 / 2 lbs.Use the gasket supplied with the kit (B, fi gure 31) , and make sure that it is positioned properly. Its shape must coincide with that of the throttle body. If not, you wil l create a vacuum leak.

2. Torque each bol t to the specs provided in the Toyota Shop Manual. Dono t ove r t igh ten .

3 . I ns ta l l t he th ro t t le posi t ion senso r p lu g , t he co i l p lug ( i f r emoved) ,and th e IAC valve conn ector .

4. Attach the PCV hose to the PCV valve on the passenger’s side ofthe eng ine .

5. Insta l l the a ir in le t tube to the throt t le body and Mass Air Flow Sensoran d reconn ect i ts hoses and tubes. Be carefu l not to dam age the sensor( f igure 32) .

6 . I ns ta l l t h e p roper cab le b racket t o the top o f t he m an i fo ld . TRDsuppl ies three throt t le cable brackets. The bracket w i th on ly oneU-shaped cable m oun t is to be used only o n T a c o m a 4 W Dm anu a l - t r ansm ission veh i c les. The b racke t w i th two U -shapedcable m oun ts is to be used on al l other m odels except 2001 and newer4Ru n n ers. F o r 2 00 1 a n d n e w er 4 R u n n e r s, u se ca b l e b r a ck e t n u m b er00602-17620-080 .

7 . Rem ove the t r ansm ission cab le c lam p f r om the m an i fo l d suppor t .C lam p is no l onger needed.

8 . Rem ovethe th ro t t le cab le/evapora t i vecan is terhose bracke t and bo l tf r om t h e st o c k m a n i f ol d . I n st a l l t h e b r a c k et o n t ot h esu p er c h a rg er a sshown ( see ar r o w A, f i gu r e 3 3 ) . I n s er t t h e t h r ot tl e c a bl e an devaporat ive cani ster hose, and in sta l l the on thethr ot t le cable and evaporat ive canister hose as show n (see arrowsB, figur e 33) .

NOTE: 2001 TACOMAWITH “DRIVE BY WIRE” THROTTLE BODY The two lower factory throttle body studs will be reused in the new supercharger installation. Take care to remove and replace both studs without damage. Torque both nuts to 18 ft./ lbs.

OE Fasteners

Zip Tys



Figure 34

B

A


9 . P lace the th ro t t le and au tom at ic t r ansm ission k ickdown cab le endsin th e ir or ig i na l th rot t l e body levers. Refer to Step 11 in Sect ion 2on Page 4 and F igu re 8 .

10 . I ns tal l t h e tr ansm ission k ickdown cab le ( see arr ow A,f igure 34) and th ro t t le cab le (see arrow B, figure 34) i nt h e b r a c k e t .

11 . P roper th ro t t le cab le tension can be accom p l ished by v iew ingF igu res 35 & 36 . Wi th a l igh t bu t f i rm p ressu re you w i l l be ab leto hea r a d ist inc t i ve “ c l i ck ” when p ressin g down (see figure35) . Re lease f inge r p ressu re and you shou l d hea r an o the r “ c l i ck ”as bracket m eets bracket ( f igure 36) .

Important: If the throttle cable is not properly adjusted, engine performace will suffer. Refer to a factory setup if necessary.

Figure 35

Figure 36

.080" - .125"Approx.

0.00"No gap




Figure 37

Figure 38

B

A

12 . Ins ta l l t he d iagnos t ic p lug b racke t and the g round con nec to r to

the dr iver ’s side of the sup ercharger . In sta l l the d iagnost ic p lu g(see arrow A, figure 37) .

13 . I ns ta l l t he fue l r e tu rn l in e b racke t t o the d r iver ’ s side o f t he man i fo ld(see arrow B, figure 37) .

14 . Usin g you r d iag ram s, and those in the back o f t h is m anu a l , doub lecheck the rout ing of vacuum hoses, cables and brackets and cor recta n y p r o b l em s ( f igure 38) .

15 . I ns ta l l t h e g rave l gua rd .

16. At tach th e groun d cable to th e bat tery.

17 . App ly the p rem iu m - fue l s t i cker s to the fue l gauge and fu e l f i l l e r doo r .

1 8 . Ap p l y a T R D b e l t r o u t i n g s ti c k er a n d t h e E x ec u t i v e O r d e r ( E O ) l a b e lto t h e un derside o f t he hood . Th e EO w i l l a le r t sta te sm og in specto r sthat the TRD supercharger has been cer t i f ied emissions legal in a l l50 states.

19 . The k i t a l so in c ludes th ree “T RD” badges and th ree “ Supercha rged”emb lem s. They shou ld be app l ied to you r t r u ck ’s f r on t f enders andta i lgate but , before you do, make sure the paint sur face is c lean anddry. Any d ir t , gr ease or wax wi l l cau se the badges to st ick poor l y.



Figure 41

D. Throttle Body and Air Tube Install ation

for 2001and newer 4Runner only wi th Drive byWire throttle system

1. Remove rubber p lug (see arr ow A, figure 39) and hose ( seearro w B, figur e 39) . Reta in th e p lug for reuse, but the hose is notused on the supercharger in sta l l .

2 . P lace the r ubber p lug on th e open a i r box n ipp le ( see arr ow,f igure 40) .

3 . The rubber p lu g fo r t he b rake booster m oves to sam e loca t ion n ipp leon supercha rger hou sin g .

4 . Th e rubber p lug f r om the me ta l vacuu m tube a t t op r ea r o f man i fo ldw i l l m ove to the ba rb on th e th ro t t le body m oun t ing su r face.

5. Rotate th e stock h eater h ose assem bly (see arro w, f igure 41)located on th e f i rewal l an d rotate approxi m ately 30 degrees up ward.Th is w i l l provide proper c learan ce away f rom re- rou ted va lve coverbreather h ose.


Figure 39

B

A

Figure 40



Figure 42


Section 4: EGR Removal and Installation

I f you r T acom a o r T-100 is equ ipped w i th an Exh aus t Gas Reci r cu l a t ion( E G R ) v a l ve (see arrow, f i gure 42) , you w i l l n eed to r emove theva lve f r om the stock in take man i fo ld an d rea ttach i t t o the TRDsupercha rge r m an i fo l d . Here ’s how :

A. Removal

1 . Loosen the EGR p ipe f r om the d r iver ’ s side exh aus t m an i fo l d . Th i sw i l l ease the r em ova l and in sta l la t ion p rocedures ( f igure 42) .

2 . Loosen o r r em ove the c lam p ho l d in g the p ipe to the back o fthe eng ine .

3 . Rem ove the two nu ts ho l d ing the EGR p ipe to the EGR va lve andseparate the two.

4. Remove the two n uts hol d in g the va lve and i ts gasket to the stud s ont h e i n t a k e m a n i f o l d .

5 . Rem ove the EGR va lve and gasket f r om the in tak e m an i fo l d and setto on e side. I f n ecessary, rem ove the EGR hose and vacuu m ho se butdon’t disconnect the two water bypass ho ses. Th ey’re the on es withthe sp r in g c lam ps.

B. Installation

1 . Rem ove the EGR b lock-o f f p l a te f r om the two studs on thesupercha rge r m an i fo ld an d us ing these nu ts and washers, ins ta l lt he EGR gaske t and va lve to the m an i fo ld and h and t igh ten(see arrow A, figure 43) .

2 . With the superch arger bo l ted to the eng in e, a t tach th e EGR valve tot h e E GR p i p e a n d h a n d t i g h t e n w i t h t h e o r i gi n a l n u t s (see arr owB, figur e 43) .

3 . Tigh ten th e nu ts ho l d ing th e EGR p ipe to the exh aus t man i fo ld( f igure 42) and to rque them to the specs p rov ided in the Toyo ta

R ep a i r M a n u a l .

4 . Torque the EGR-pipe- to-EGR-valve nuts and the EGR-valve- to-m an i fo ld nu ts to the specs p rov ided in the Toyo ta Repa i r M anu a l .

5 . I ns ta l l t he p ipe clam p to the stud on the back o f t he eng i ne andt i g h t en t h e n u t .

Figure 43

BA

page 19




Supercharger Instructi on FAQ’s

1. Would it be a good idea to install a fuelpressure regulator along wi th the supercharger?

No. Af ter extensive test in g, TRD ha s learned th at th e fue l systemhas su f f i c ien t capac i t y to del i ve r t he add i t iona l f ue l t o m a tch theadd i t iona l a i r i ndu ced by the supercha rge r.

2 . I h a v e h e a rd o f s o m e i n c i d e n t s o f t hesupercharger causing engine pinging becauseo f i n a d e q u a t e fuel supply. I ’ve also heard

that the Kenne Bell Boost-A-Pump m ay be asolution for this issue.

Th e Toyo ta E lec t r on ic Con t ro l Un i t ’ s (ECU) p rog ram cons tan t ly“ lea rns and ad ju sts. ” Wh en the d r iv in g st y le chan ges— as when asupercha rge r i s in sta l led— the ECU w i l l r equ i r e a few hu ndredm i les to lea rn an d ad ju st f o r t he d i f f e rence . Dur in g th i s pe r iod ,u n d e r c er t ai n t r an si t o ry c o n d i t i o n s ( r a p i d t h r o t t l e o p en i n g , fo rex a m p l e ) , t h e en g i n e m a y “ p i n g ” f or a sec on d w h i l e t h e E CUa d j u st s f u e l en r i c h m en t a n d i g n i t i o n t i m i n g . U n l e ss th e “ p i n g i n g ”cont i nu es over a per iod o f susta in ed dr iv in g, th i s does not po se ap rob lem. T he Boost - a -Pum p p rodu c t r a ises the vo l tage supp l i ed tot h e v eh i c l e’s el ec tr i c f u e l p u m p , w h i c h c a n i n c r ea set h e p u m p ’stheoret ica l output capaci ty and del ivery pressure. The Toyota OEfuel pump has adequate del ivery capaci ty, and the fue l pressureregu la to r i s un changed when th e supercha rge r i s in sta l led . Th ism eans tha t t h e system w i l l st i l l be r egu l a ted a t app rox im a tely48-52 psi , so there ’s no need for h igher output .

3. What air fi lter does TRD recommend?

A new fac to r y a i r f i l t er w i l l wo rk , f o r best r esu l t s TRD recom m endsthe use of ou r washab le / r eusab le h igh f low a i r f i l t e r s ava i lab le a tthe nearest Toyota dealer or by ca l l in g TRD direct a t (800) 688-5912.

4. What is the added benefit if I also installed TRDheaders and an exhaust system?

Add i t ion a l power can be ga ined f r om headers and a pe r fo rm anceexhaust system. At the t ime of th is pr in t ing, TRD of fers a l l

sta i n less- steel -h ea der s an d ca t- back ex h au st system s form ost vehic les equipp ed with the 5VZFEeng ine .

5. There has been some confusion as to whichvehicles the supercharger works best on.Please clari fy.

Whi le the supercha rge r w i l l f i t t he eng in e , t he E lect r on ic Con t ro lUn i t s (ECUs) u sed in 1995 and 1996 T-100 and Tacom a t r ucksdo no t r espond as we l l t o supe rcha rg i ng as do the 1997 andlater vehic les. For th is reason, TRD does NOT recommend thesupercha rge r fo r t he 1995 and 1996 Tacom a and T -100 t r ucks .

6. I don’t see an EGR setup on my truck.

How do I know i f I have one?Refe r to figu r es 14 , 44 and 45 in th e ins tr uc t ion m anu a l .

7. How wil l installi ng a supercharger affectmy gas mil eage?

Dur ing pa r t - th ro t t le d r iv ing , a round town and h ighway c ru ise ,fo r exam p le , t he supercha rge r shou ld n o t no t i ceab ly a f fect gasmileage. Overa l l fue l mi leage decreases with increased fu l l throt t leoperat ion, and decreases more when supercharged. Simply put ,add i t iona l power r equ i r es add i t iona l f ue l and du r i ng boos ted ,fu l l - power opera t ion , t h e fue l m i leage w i l l decrease m ore thanwhen th e eng in e is no rm a l ly asp i r a ted .

8. I would like to install the supercharger myself.Does i t hurt the stock warranty or does thewarranty stay for everything but the supercharger?

Regard less of wh ether the sup ercharger is in sta l l ed by the Toyotad ea l er o r b y y o u , t h e T o y o ta N e w Ca r W a r r a n t y i s u n a f f e c t ed . I f t h esu percha rge r is in sta l led a t thedea le r sh i p , thewar ran tyon th esu perch arger is for e i ther 5 years or the rem ain i n g vehi c le power tra in

w a r r a n t y, ( w h i c h e v er c o m e sf i r s t) . I f t h e su p e r c h a r g e r i s i n s ta l l e d b yo the r than a Toyo ta dea ler sh i p , t he war ran ty on the supercha rge r i sfo r one yea r . Each supercha rger k i t i nc lu des a war ran ty ca rd , wh i ch

fu l l y exp la ins the de ta i l s. Af ter r ead ing the war ran ty in fo rm a t ion ,

p lease f i l l ou t t he ca rd and m a i l i t back to TRD .

9. Do I have to change my exhaust system?

No, however u pg rad ing to TRD headers and a ca t - back exhau stsystem is st rongly recommended for best per formance.




10. If I do choose to take it to a Toyota dealer to beinstalled, can you recommend one in my area?

TRD’s websi te , www.t rdusa.com, has a dealer locator funct ion. I fyou p re fer , p lease cal l TRD ’s he lp l in e a t ( 800 ) 688 -5912 , and wew i l l be g lad to assis t you in loca t ing a TRD stock ing dea le r.

11. How much boost should the TRD superchargermake? Is a small er pulley available for thesupercharger, so that i t might make more boost?

The TRD supercharger comes with one pul ley s ize only, designedto de l i ver app rox i m a tely 7 psi o f boost p ressu re . Th e pu l leysize ,

a s y o u u n d e r st a n d , a f f e c t st h e d r i v e r a t i o b e tw e en t h e su p e r ch a r g era n d t h e en g i n e. I n c r ea si n g t h e s p ee d o f t h e su p e r ch a r g er r el a t i v et o t h e en g i n e w i l l r a i s e t h e b oo st ed m a n i f ol d p r essu r e, b u t n o t t h ea c tu a l t o r q u e a n d p o w er o u t p u t o f t h e en g i n e. T R D h a s co n d u c t edhu ndreds o f hou r s o f dynam om ete r test ing , and fou nd in som ecases that ra is in g th e boost leve l m ay actual ly decrease engi neper form an ce. Th e pul l ey size, and boost leve l , o f the superch argerha ve been designed to achi eve the best m ix o f per form an ce,e ff i c iency and overa l l r e l iab i l i t y . Chan g ing the pu l l ey WILL vo idthe war ran ty on the supercha rge r .

12. Does it matter if the transmission is manualor automatic?

The supercharger w i l l work proper ly regard lessof t ransmission type.

13. Do I need to add a transmi ssion cooler i f I donot intend to do any towing?

A t ran smi ssion cooler provides added protect ion for yourau tom at ic t r ansmi ssion , r ega rd less o f you r i n tended use.T R D s t r o n g l y r ec o m m en d s i n s t al l i n g t h e t r a n sm i ssi o n co o l eron an y veh i c le tha t m ay be used fo r t ow in g , espec ia l l y i f a

supercharger is insta l led.

14. Do I have to change the vehicle’s computer(ECU)? Do you suppose it’s possible to changeout the 1995 or 1996 computer (ECU) with the‘97 or ‘98 model?

TRD does NOT recom m end us ing any com pu te r fo r you r veh ic leo the r than the one tha t i s made fo r t he spec i f i c veh ic le by Toyo ta .TRD o f fe r s no m od i f ied o r a l t e rna t ive compu ter s, as the TRDsupercharger ha s been design ed to be com pat ib l e wi th th e factorycompu te r .

TRD does not recommend the addition of our Supercharger Kits to any 1994-1995 T100, Tacoma or4Runner. The older vehicle engine management electroni cs does not lend itself to supercharging.




Figure A

Notes:

2001 and newer

4Runner 2WD

Year

Model

Figure B

Notes:

2001 and newer

4Runner 4WD

Year

Model




Figure C

Notes:

2001 and newer

Tacoma 2WD

Year

Model

Figure D

Notes:

1997-2001

Tacoma 4WD

Year

Model

1996-2000

4Runner 4WD

Year

Model




Figure E

Figure F

Notes:

Notes:

1997-1999

Tacoma 2WD, EGR

Year

Model

2001

Tundra V6

Year

Model




Figure G

Figure H

Notes:

P/S Valve Circuit not on all

models. Installation requires

an addit ional 5/16” “ T” -Fitt ing

that is not included in the kit.

Notes:

One-Way ValveInstall ation Diagram

1997-1998

T-100 2WD & 4WD

Year

Model



Toyota Racing Development

www.trdusa.com

1.800.688.5912

Symptom Possible Causes Corrective Action

I d l es r ou gh , “ p i n g s” L ea n c on di t i o n — Ch eck vacu u m l i n e con n ect i on s fo r l eak s an d crack ed en ds.( T r ou b l e Code PO171— Lean Code) va cu u m l ea k

Rev iew fac tory serv i ce m anu a l fo r p roper fac tory vacuum rou t i ng .

Rev iew ins truc t i ons fo r p roper vacuum l i ne rou t i ng .

Check i ns ta l l a t i on o f the TRD thro t t l e body gasket . I f gasket i s i ns ta l l edi m p ro p er l y , a v a c u u m l e a k w i l l o c c u r .

Recheck to rqu e on th ro t t l e body bo l ts.

Leak a t man i fo ld gasket .

Recheck to rque on i n take man i fo ld bo l ts .

P i n gs du r i n g accel er a t i on Low octan e fu el Fi l l tan k w i th PREMIUMFUEL.

Compu ter has ye t to Dr i ve severa l hu ndred m i les i n d i f fe ren t d r i v ing m odesa dj u st to su per ch ar ger ( N ot al l st ead y- st at e h ig hw ay cr u isi ng , f or ex am p le) .

I n su f fi ci en t fu el d el iv er y Fu el f il ter ol d— r ep lac e. Fo ll ow f ac tor y d ia gn o si s a n d r epl acem ent p rocedure s.

Fue l p ressure l ow . Fo l l ow fac tory d iagnos is and rep lacement p rocedures.

In jec tor(s ) c logged. Fo l l ow fac tory repa i r / rep lacement p rocedures.

Low boost Bel t sl i ppi n g Ch eck con d i t i on o f bel t— oi l y, wor n , h i gh m i l eage.

Ai r f i lter d i rty Ch eck /r ep l ace a i r f il ter . A d i rty f i lter restr icts th e ai r i ntak e. T RDdyn otests have shown tha t th e TRD a i r f i l te r i s am ong th e best on the m arke tfo r f l ow and f i l te r i ng char ac ter i st i cs .

T h r ot tl e n o t f u l ly o pen ed R ec h ec k an d ad j u st th e t h r ot t le c ab l e a n d t r an sm i s si o n c ab l e. Be su r e t h atfu l l depress ion on th e gas peda l ach ieves fu l l th r o t t l e open ing a t th ethro t t l e body.

Check the supercharger bypass va l ve fo r p roper opera t i on .

M a kes a m o d er at el y l ou d n o ise N or m a l su p er ch a rg er N o r em e dy. Su p er ch a rg er s a re a n a ir p u m p a n d t h e p u m p in g a ct io n i su n der fu l l th r o t t l e— i n tak e n o i se sou n d i m possi b l e w i th ou t som e n o i se. Ca l l T RD fo r fu r th er d i agn osi s.

R at tl in g a t i dl e— g oes a wa y N or m a l su p er ch a rg er Sl ig h t r at tl e a t i dl e i s n o rm a l , b u t o n ly i f n o ise sh a rp ly d ecr ea ses a ta t j u st above i d l e sou n d 400 - 500 rpm above i d l e. Ca l l T R D fo r fu r th er d i agn osi s.

Rat t l i n g above id le— gets l ouder Dr i ve hou s ing bear ing Ca l l TRDfor fu r th er d iagnos is .w i t h h i g h e r r p m o r l o u d e r w i t h w e ar o r b a c k l a shm ore boost p ressure

I d l er pu l l ey bear i n g Dia gn oseb yr em ovin g b e l t f r o ms u p erch arge r a n d r u n n i n g e n g i n e for l ess t h a nw ea r o r ex c essi v e f r ee pl a y 3 0 se co n d s. I f n o i se c on t i n u e s, so u r c e o f p r o bl em i s n o t wi t h i n su p er c h a rg er.

T h r o t tl e c ab l e d o es n o t I n c o r r ec t b r a ck e t i n st a l le d T h e T R D Su p er c h a r ger k i t h a s t h r ee b r a ck e ts. T h e si n g l e c a bl e w i t h t h r o t tl eproper l y l i n e u p l ever m ou n t b rack et i s fo r u se on T acom a tr u ck s w i th 4WD an d m an u a l

t ransm ission . Th ese veh ic les have a sl i gh t l y d i f fe ren t th r o t t l e a rm . A l l o ther

veh ic les shou ld use the two-cab le mount. Manua l t ransmiss ion veh ic lesleave the t ransm ission cab le m oun t empty . Use bracket 00602-17620-080 fo r 2001a n d n e w e r 4 R u n n e r .

Su p er ch a r ger b el t j u m p s M i sa l ig n ed p u l ley / id l er Ch ec k t o b e su r e t h at t h e c ra n ksh a ft p u ll ey i s p r op er ly t i gh t en ed . R e- ti g h tenacross pu l l ey g r ooves to speci f i ca t i on s g i ven , fo l l ow th e pr ocedu re i n th e factor y m an u a l .

D am aged pu ll eys Be su re th at th e pu ll eys a l l r un tr u e— n o eccen tr ici ty.

Loose pu ll eys Ch eck to be su re th at th e cra nksh af t pu ll ey i s p roper ly ti gh ten ed. R e-t ig htento spec i f i ca t i ons g i ven, fo l l ow the procedures i n the fac tory m anu a l .

Su p er c h a r ger b el t l ea v es g r e y/ b l a ck N o r m a l b r ea k - i n r esi d u e N o c o rr ec t iv e a ct i o n . B el t sh o u l d b e f u l l y b r o k en i n a f ter 2 0 00 m i l e s.powder on dr i ve hous ing and o th er a reas

Supercharger appears to l eak o i l F ron t sea l no t fu l l y No im m edia te correc t i ve ac t i on . Sea l shou ld be fu l l y m ated to pu l l ey a f te rf r om dr i ve h ou si n g brok en i n 2000 m i l es. I f l eak i n g con t i n u es, con tact T R D.



IMPORTANT WARRANTY INFORMATION

Dealers – Technic ians:Fa i lu re to com p le tely and p rope r ly f i l l ou t and m a i l i n you r cus tom er ’s War ran ty Reg ist r a t ion Card m ay resu l t in possib le r educ t ion o rcom p le te den ia l o f f u tu r e war ran ty c la im s.

Customer installed units:Fa i lu re to com p le te ly and p rope rly f i l l ou t and m a i l in you r War ran ty Reg ist r a t ion Card m ay resu l t in possib le r educ tion o r com p le teden ia l o f f u tu re war ran ty c la im s.

Toyota TRD 3.4 5VZFE Supercharger Install Instructions

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