LHD/RHD TURBO KIT MR 2 1ZZ-FTE ATTENTION Read this installation instruction manual carefully, before you start the installation. Installing this turbo kit requires a skilled “TOYOTA Pro Technician“ or similar. When opening packages, first check the contents and the quantity using a check sheet. After installation operation is started, request for the missing parts may not be accepted. INSTALLATION INSTRUCTION MANUAL ISS REVISION RECORD DATE REVR. 0 1 NEW Revision Oct. 05 Oct. 05 1.0 1.
TABLE OF CONTENTS TABLE OF CONTENTS ............................................................................................................................................3 PRECAUTIONS ......................................................................................................................................................6 PREPARATION ......................................................................................................................................................7 1.
10. Intercooler preparation ...........................................................................................................................40 1. Install lower bracket. ............................................................................................................................40 2. Install upper bracket. ...........................................................................................................................40 11. Pre-catalyser heat shield preparation ........
17. Install interior compartment ...................................................................................................................61 1. Install control-unit assembly. (manual transmission only) ...................................................................61 2. Remove automatic transmission control-unit (automatic transmission only). ......................................61 3. Install control-unit assembly (automatic transmission only). .............................................
PRECAUTIONS PLEASE READ THOROUGHLY THESE PRECAUTIONS BEFORE INSTALLING THE CHARGER KIT Do not pinch the rear wring or harness in the tightened part. When passing the wires through the dashboard or other panels, use a grommet to ensure waterproofing. Protect the wiring with tape when it is passed through a hole. Protect the car with fender covers and so on. Use the correct tool when tightening bolts and nuts. Tape Grommet When disconnecting a connector, be sure to grip the connector body.
PREPARATION 1. 2. SST (Special Service Tools) 1 09032-00100 Oil pan remover 2 09228-06501 Oil filter wrench 3 09816-30010 Oil pressure switch wrench 4 AM 300-38300 Jack nut tool Lubricants / Liquids Engine Coolant Ethylene-glycol base Engine oil API grade SH energy-conserving II or SJ energy-conserving or ILSAC multigrade engine oil. Refer to the owners manual for the viscosity to recommend.
VEHICLE LIFT LOCATIONS In this manual, a plate type or swing arm lift is recommended. See the description below for details of the supporting and attachment positions. Plate type lift: (a) Place the vehicle over the centre of the lift. (b) Align the cushion gum ends of the plate with the attachment lower ends (A,B). (c) Align the attachment upper end with the rocker flange front notch.
PARTS 1. Location Numbers with a character (Ex. 14-1) in “PARTS LOCATION” correspondent to numbers in the text and the illustration in “INSTALLATION PROCEDURES” as well as “No.” in “PARTS LIST”. 1.1.
1.2.
1.3.
1.4.
1.5.
1.6.
1.7.
1.8.
1.9.
1.10.
1.11.
2. Parts List No. 1.0 KIT, AIRBOX QTY 1 PART No. AM300-32400 1-1 Bellow with spring clamps 1-2 Airfilter, sport 2.0 KIT, INTAKE TURBO 1 1 1 AM183-17000 AM181-50000 AM300-32500 2-1 Hose clamp 50-70 2-2 Pipe Airbox turbo 2-3 Bracket, pipe airbox-turbo 2-4 Hose, intake Turbo 2-5 Air connection 2-6 Bolt, hexagon socket M10X30X1.5 2-7 Washer 2-8 Nut, hex head M10X1.5 2-9 Spring washer 2-10 Bolt, hex head M6X1X12 2-11 Nut, hex head M6X1 2-12 Edge protection 3.
7.0 KIT, INTERCOOLER 7-1 Intercooler 1 1 AM300-33000 AM181-82000 7-2 Bracket, intercooler, No.1 7-3 Bracket, intercooler, No.2 7-4 Bracket, intercooler, No.3 7-5 Cushion M8 7-6 Bolt, hex head M8X12X1.25 7-7 Nut, hex head M8X1.25 7-8 Bolt, hex headM10X20X1.25 8.
14-4 Pipe, oil runback 14-5 Hose, connection to oil pan 14-6 Hose clamp 16-25 14-7 Gasket 14-8 Seal ring, oil runback pipe 15.0 KIT, OIL PRESSURE SWITCH 15-1 Extension, oil pressure switch No.1 15-2 Extension, oil pressure switch No.2 1 1 2 2 1 1 1 1 AM869-79000 AM869-80000 AM300-27100 90430-12031 AM902-11000 AM300-33800 AM300-26300 AM300-26400 15-3 Copper Seal ring 16.0 KIT, INFLOW WATER, TURBO 16-1 Pipe bended Water turbo 16-2 adapter, turbo, water, No.2 M16X1.5//M14X1.
23-3 Sensor, Temperature 23-4 Power Control unit 23-5 Relay 23-6 Fuse, 15 Ampere 23-7 Arma Flex 23-8 Tie Wrap 23-9 Tie Wrap with socket 24.0 KIT, FIXING, ELECTRONIC 24-1 Bracket, Sensor, Temperature 24-2 Bolt, hex head M6X30 24-3 Bracket, Power Control unit 24-4 Nut, flat M12X1.5 24-5 Washer for temperature sensor 12 mm 24-6 Nut for relay M5X1 24-7 Nut for ECU M6X1 24-8 Nut for bracket M8X1.
3.
Exhaust pipe onto turbo Oil return pipe Ground bolt Cooling fan cover Lambda sensor No. 1 Exhaust manifold heat shield Lambda sensor No. 2 Spark plugs Ignition coils Control-unit assembly (manual) Control-unit assembly (automatic) Automatic control unit Wiring harness ground connection 16 20 9 6 44 20 44 25 9 13 13 13 9 160 200 90 60 450 200 440 250 90 130 130 130 90 11.5 15 6.6 4.4 32 15 32 17.9 6.6 9.3 9.3 9.3 6.
INSTALLATION PROCEDURES 1. Introduction 1.1. SI UNIT. The UNITS given in this manual are primarily expressed according to the SI (international System of Units), and alternately expressed in the metric system and in the English system. 1.2. CAUTION * NOTICE * HINT. CAUTION: There is a possibility of injury to you or other people. Be sure to observe the contents. NOTICE: There is a possibility of damage to the components or vehicle. Be sure to observe the contents.
1.5. AIR HOSE AND CLAMP. NOTICE: – Follow the instructions below. Otherwise the hose may come off or intake air may leak, disabling driving due to engine stop. – Wrapping the hose clamp too tightly may damage the part or related parts. Example: 3-5mm (a) The paint mark on the air hose is the reference for positioning. Align the mark with that of the pipe for fitting. (b) When fitting the hose to the pipe, make sure to push in the hose until it reaches the paint mark.
2.
CONTINUED U U
Vehicle preparation 1. REMOVE CARBON CANISTER. R C (a) Remove the clamp of the vacuum hose. R: Clamp (b) Disconnect the vacuum hoses from the carbon canister. (c) Remove the carbon canister from its bracket by sliding it upwards. R: Carbon canister R B EN E GIN OIL A 2. REMOVE HARNESS CLAMPS. A B (a) Cut the harness clamp (A) from the harness. U: Harness clamp (b) Reposition the harness (B). (c) Reinstall the carbon canister (d) Reconnect the carbon canister hoses with the clamp.
3. HOLE PREPARATION. A Ø 11.2 mm (a) Drill the hole out to 11.2 mm. (b) Remove burrs and protect the hole with anti-corrosion primer. (c) Insert the steel jack nut using the special tool.(SST AM300-38300) K: Jack nut tool (26-8) K: Jack nut (20-3) B C K 4. HARNESS FIXATION. (a) Mount the harness clamp onto the vehicle harness. K: Harness clamp. (20-1) (b) Mount the clamp with 1 bolt and bracket into the jack nut. K: Bolt (20-2) K: Bracket No. 1 (19-2) Torque: 3 Nm K K K 5. HARNESS GROMMET HOLE.
4. Airfilter box heat shield preparation 1. PREPARATION HEAT SHIELD. (a) Mark the position where to cut by using the template. K: Template (27-2) (b) Remove the marked part, use an air driven saw or plate cutting tool. (c) Remove sharp edges and install protection strip. K: Protection strip.
5. Oil-sump preparation 1. INSTALL OIL RETURN ADAPTER. (a) (b) (c) (d) (e) (f) Mark the position of the oil return hose adapter. Punch-mark the drilling position.(spot-weld position) Pre-drill a 4 mm hole. Pre-drill to 6.5 mm Drill the hole out to 12mm. Remove burrs. Ø 4 mm Ø 6,5 mm Ø 12 mm (g) Install the oil return adapter with the nut and copper gasket and Loctite No.270 K: Adapter (14-1) K: Nut (14-2) K: Copper gasket (14-7) Torque: 45 Nm K K K (h) Install the oil drain plug with a new gasket.
6. Underbody protection preparation 1. UNDERCOVER PREPARATION. (a) Remove the 10 pop-rivets from the undercover. (b) Remove from the bottom side (engine side) the plastic reinforcement out of the sound insulation. NOTICE: Before removing the plastic reinforcement cut it with scissors. (c) Fix the template to the undercover with tape. K: Template (27-4) (d) Mark the position where to cut. (e) Cut the marked position. (f) Remove the template. (g) Turn the cover with the engine side facing up.
(j) Place the undercover on the floor (engine side facing down) (k) Remove drain plug cover. U (l) Prepare the template. K: Template (27-1) K (m) Fix the template onto the undercover with tape. (n) Mark the position where to cut with a marker. (o) Mark the 6 hole positions into the undercover. (p) Remove the template. (q) Pre drill 6 holes of 4mm. (r) Drill the 6 x 11.2 mm holes into the undercover. 6x Ø 4 mm Ø 11,5 mm (s) Cut the marked position out of the undercover with a cutting tool.
(t) Install the aluminum bracket-spoiler onto the undercover with 3 aluminum jack nuts using the jack nut tool.(SST AM300-38300) K: Bracket spoiler (21-1) K: Aluminum jack nuts (3 pcs.) (21-4) K: Jack nut tool (26-8) K K K K K (u) Install the aluminum bracket onto the undercover with 3 aluminum jack nuts using the jack nut tool.(SST AM300-38300) K: Aluminum bracket (21-3) K: Aluminum jack nut (3 pcs.
7. Engine cover preparation 1. ENGINE COVER PREPARATION. (a) Mark the position where to cut. Use template 27-3 (b) Remove the marked part, use an air driven saw.
8. Cooling fan preparation 1. INSTALL COOLING-FAN. (a) Position the cooling-fan on the bonnet cover. K: Cooling-fan (22-2) K: Bonnet cover (22-1) (b) Install 4 bolts and nuts. K: Bolt (4 pcs.) (22-3) K: Nut (4 pcs.) (22-4) Torque 6 Nm 4x K 4x K K NOTICE: Ensure that the harness connection is facing the right direction. K 2. INSTALL BRACKET TO COVER. 2x K (a) Install temperature sensor bracket to cover K: Bracket (24-1) K: Nut (2x) (24-11) K: Bolt (2 pcs.) (24-10) Torque: 10 Nm K 2x K 3.
9. Inlet pipe preparation K 1. INSTALL VACUUM HOSE ADAPTER. (a) Put Loctite 270 on the hose adapter. (b) Install the hose adapter into the inlet pipe. K: Vacuum hose adapter (2-5) K: Inlet pipe (2-2) Torque: 25 Nm K 2. PREPARATION OF VSV. (a) Mark the VSV bracket for drilling (b) Drill a 6.5 mm hole into the VSV bracket. R: VSV R Ø 6.5 mm 3. INSTALL VSV. K R (a) Install the VSV onto the inlet pipe with the bolt.
10. Intercooler preparation 1. INSTALL LOWER BRACKET. K (a) Install the rubber mounting onto the intercooler with Loctite 243 and handtighten. K: Rubber mounting (7-5) K: Intercooler (7-1). (b) Install the bracket (1) onto the rubber mounting with a nut. (hand tighten). K: Bracket Intercooler No. 1 (7-2). K: Nut (7-7) K 1 K K 2. INSTALL UPPER BRACKET. K K K 2 K 3 K K (a) Install the bracket (2) onto the intercooler with a bolt (hand tighten while using Locktite 243). K: Bracket Intercooler No.
11. Pre-catalyser heat shield preparation 1. INSTALL PRE-CATALYSER HEAT SHIELD. (a) Install the heat shield with the 2 clamps and 4 bolts onto the catalyser. K: Catalyser (10-1) K: Heat insulation No. 2 (10-2) K: Bolts (4 pcs.) (10-6) K: Bracket (2 pcs.) (10-3) Torque: 6 Nm K K 4x K 2x K NOTICE: Ensure clearance between the clamp and the exhaust tube of 5 mm. NOTICE: Ensure location is parallel to flange.
12. Turbo control system preparation 1. TURBO CONTROL SYSTEM PREPARATION. K K K K K K K K K K K K (a) Install the power control-unit onto the bracket using the 2 bolts and 2 nuts. K: Bolt (2 pcs.) (24-2) K: Control-unit (23-4) K: Power Control-unit bracket (24-3) K: Nut (2 pcs.) (24-7) Torque: 8 Nm (b) Install the relays onto the bracket using 2 bolts and 2 nuts. K: Relay (2pcs.) (23-5) K: Bolt (2 pcs.) (24-9) K: Nuts (2 pcs.) (24-6) Torque: 6 Nm 2. INSTALL CONTROL-UNIT HARNESS.
13. Turbo preparation 1. TURBO PROTECTION. CAUTION: Cover all the inlet and outlet holes with protective tape to avoid parts from falling in. 2. REMOVE PLATE WITH PRESSURE ACTUATOR. K R R R (a) Remove the pressure actuator bracket by removing the clip and 2 bolts. R: Clip R: Bolt (2 pcs.) R: Pressure actuator. K: Turbo charger (3-1) CAUTION: Do not damage nut assurance. R 3. TURBO LUBRICATION.
5. INSTALL WATER OUTLET HOSE. K (a) Install the outlet hose onto the outlet adapter. K: Water outlet hose (17-1) Torque: 14 Nm NOTICE: Ensure that the connection is pointing into the right direction (in line with exhaust manifold connection) 6. INSTALL WATER INLET TUBE. (a) Install the water inlet tube onto the water inlet adapter. K: Water inlet tube (16-1) Torque: 12 Nm NOTICE: Ensure that the water inlet tube is pointing into the right direction. K 7. INSTALL OIL PRESSURE TUBE.
9. INSTALL PRESSURE ACTUATOR HOSE. (a) Insert the pressure hose into the heat protection hose K: Pressure hose (18-2) K: Hose Heat protection (18-1) (b) Install the pressure hose with the 2 clamps. K: Clamp (2 pcs.
14. Installation engine compartment 1. INSTALL EXHAUST MANIFOLD GASKET. (a) Place the new gasket onto the cylinder head studs. K: Gasket (9-2) K 2. INSTALL EXHAUST MANIFOLD. (a) Install the exhaust manifold onto the cylinder head using the 5 nuts. K: Nuts (5 pcs.) (9-3) K: Exhaust manifold (9-1) Torque: 37 Nm K K 5x 3. POSITION TURBO CHARGER. (a) Position the Turbo charger underneath the exhaust manifold. K: Turbo charger (3-1) (b) Position the gasket between the manifold and the Turbo charger.
5. INSTALL TURBO CHARGER BRACKET. K K K K K (a) Install the bracket with short bolt and washer to the engine (hand tighten). K: Bolt (5-4) K: Washer (5-5) K: Bracket (5-2) (b) Install the bracket with long bolt, washer and spacer to the Turbo charger (hand tighten). K: Bolt (5-3) K: Washer (5-5) K: Bush (5-6) K B 4x A 6. TIGHTENING TURBO CHARGER. (a) Tighten the 4 bolts of the Turbo charger. Torque: 28 Nm (b) Bend the locking plates against the side of the bolt.
(f) Install hose on engine side with a clamp. R: Clamp Torque: 3 Nm R 8. INSTALL WATER OUTLET CONNECTIONS. (a) Install the clamps on the water outlet hose. K: Water outlet hose (17-2) K: Hose clamp (2 pcs.) (17-3) Torque: 3 Nm (b) Install the water outlet hose between the Turbo charger water tube and the engine water connection. K K K NOTICE: ENSURE THAT THE CLAMP MECHANISM IS FACING DOWNWARDS TO AVOID DAMAGE TO THE INLET TUBE (TO BE INSTALLED LATER) 9. WATERHOSE FIXATION.
15. Installation engine compartment lower 1. APPLY LIQUID GASKET TO OIL PAN. (a) Apply the liquid gasket onto the clean sump surface. NOTICE: Liquid gasket 08826-00080 2. INSTALL OIL PAN. 14x R (a) Within 3 minutes after applying the liquid gasket install the oil-sump onto the engine using the 14 bolts and 2 nuts. R: Bolt (14 pcs.) R: Nut (2 pcs.) (b) Tighten the bolts and nuts carefully first with 5 Nm and after with the final torque. Torque: 9 Nm (c) Install plastic flywheel cover. 3.
5. INSTALL OIL PRESSURE SWITCH. (a) Install the oil pressure switch into the adapter using Loctite 243. Use SST 09816-30010 R: Pressure switch Torque: 13 Nm (b) Connect the oil pressure switch connector to the pressure switch. NOTICE: Turn oil filter until the o-rings touches the flange. Turn oil-filter 270° by hand. R 45˚ 6. INSTALL INTERCOOLER. K K K (a) Position the intercooler assembly underneath the gearbox.
8. INSTALL OIL PRESSURE TUBE. K (a) Install the oil pressure tube onto the inlet pipe using the clamps. K: Clamp (2 pcs.) (13-4) K 9. INSTALL INTERCOOLER OUTLET PIPE. (a) Position intercooler outlet pipe, hose and 2 hose clamps. K: intercooler outlet pipe (8-1) K: Hose intercooler side (8-2) K: Clamp (2 pcs.) (8-4) (b) Tighten outer hose clamp on intercooler side. Torque: 3 Nm (c) Pull outlet pipe 5 mm out of the hose and hand tighten inner clamp.
(h) Tighten the Intercooler fixation bolts. Torque: 1. Bolt 16 Nm 2. Bolt 16 Nm 3. Nut 12 Nm 4. Nut 12 Nm 5. Nut 12 Nm 6. Bolt 12 Nm 1 5 4 2 6 3 NOTICE: When applying the correct torque to the fixation bolts ensure the correct positioning of the Intercooler and clearance from surrounding parts.
16. Installation engine compartment upper 1. INSTALL TURBO INLET PIPE. (a) Position the turbo inlet pipe, hose and 2 clamps. K: Pipe, Airbox turbo (2-2) K: Hose (2-4) K: Clamp (2 pcs.) (2-1) (b) Tighten outer hose clamp on turbo charger side. (c) Pull inlet pipe 5 mm out of the hose and hand tighten inner clamp. K K K K 2. INSTALL TURBO INLET PIPE BRACKET. (a) Install the bracket with the 2 bolts onto the inlet pipe. K: Bolt (2 pcs.
(d) Wrap the T-junction with the anti-rattle foam. K: Anti-rattle foam (25-4). K 5. MODIFY ENGINE VENTILATION HOSE. R Cu ttin g li ne r s fo ho (a) Modify the ventilation hose as indicated on the template. K: Template (27-5) se K 6. INSTALL ENGINE VENTILATION HOSE ONTO ENGINE. R (a) Install the engine ventilation hose with the hose clamp onto the engine connection. R: Ventilation hose K: Clamp (12-1) Torque: 3 Nm (b) Install distance clamp onto the hoses. K: Clamp (12-4) K K 7.
8. INSTALL VSV CONNECTIONS. (a) Install the vacuum hose 1 onto the VSV. 1 9. INSTALL AIR FILTER. U K (a) Remove the air filter from the air filter box. U: Air filter. (b) Install the high performance air filter into the air filter box. K: Air filter, sport (1-2) 10. PREPARE AIR FILTER BOX COVER. (a) Install the bellow onto the air filter box cover using the spring clamp. K: Bellow with spring clamps (1-1) K 11. INSTALL AIR FILTER BOX COVER (a) Install the cover onto the air filter box.
12. INSTALL EXHAUST PIPE PRE-CATALYSER. K K 3x (a) Position the exhaust pipe next to the turbo outlet side. K: Exhaust pipe pre catalyser (10-1) (b) Install the exhaust pipe onto the turbo charger using the locking plate and bolts.(handtighten) K: Locking plate No. 2 (4-4) K: Bolt (3 pcs.) (4-1) K 13. INSTALL EXHAUST PIPE BRACKET. (a) Remove the 2 bolts of the gearbox mounting bracket. R: Bolt (2 pcs.) (b) Install the exhaust pipe bracket using the bolts.
15. INSTALL OIL RETURN HOSE. (a) Install the oil return hose onto the oil return pipe and oil pan adapter using 2 clamps. K: Clamp (2 pcs.) (14-6) K: Oil return hose (14-5) K K K 16. INSTALL WIRING HARNESS. K K K 200mm K K K K (a) Insert the 15A fuse into the wiring harnesss fusesocket. K: 15A Fuse (23-6) (b) Insert the vacuum hose into the grommet. Ensure that that 200mm of vacuum hose and wiring harness length is in the interior compartment.
G EN INE OIL (j) Route the harness branch with the ground connection towards the original ground connection bolt. (k) Install the ground connection. Torque: 9 Nm (l) Route the harness towards the bonnet hinge and follow the original vehicle harness. NOTICE: Ensure that there is enough harness slack to avoid harness damage due to engine movement. Ensure that the harness is secured every 15 cm using the tie wraps. K: Tie wraps (23-8) 17. INSTALL COOLING FAN COVER.
18. INSTALL LAMBDA SENSOR NO. 1 (a) Install the lambda sensor into the exhaust manifold. R: Lambda sensor. Torque: 44 Nm R 19. INSTALL EXHAUST MANIFOLD HEAT SHIELD. K K K K (a) Install the exhaust manifold heat shield onto the manifold using the 4 bolts . K: Heat insulation No. 1 (11-1) K: Bolt (4 pcs.) (11-2) Torque: 20 Nm K (b) Connect the lambda sensor connector to the vehicle harness. (c) Fix the sensor connector to the inlet pipe bracket. 20. INSTALL LAMBDA SENSOR NO..
(b) Install the lambda sensor harness with the clip into the bracket. K: Clip (19-1) K 21. SPARK PLUG EXCHANGE R R R R (a) Remove the 4 bolts of the coils. R: Bolts (4 pcs.) (b) Remove the ignition coils. (c) Remove the spark plugs. (d) Install new spark plugs. K: Spark plug (SK20R11-iridium) (26-2) Torque 25 Nm (e) Install the ignition coils with 4 bolts. R: Bolts (4 pcs.
17. Install interior compartment 1. INSTALL CONTROL-UNIT ASSEMBLY. (MANUAL TRANSMISSION ONLY) (a) Install the control-unit assembly onto the studs using 3 nuts. K: Nut (3 pcs.) (24-8) Torque: 13 Nm K K K 2. REMOVE AUTOMATIC TRANSMISSION CONTROL-UNIT (AUTOMATIC TRANSMISSION ONLY). (a) Remove the 3 nuts. (b) Remove the control-unit and put it aside. (do not disconnect the connectors) 3. INSTALL CONTROL-UNIT ASSEMBLY (AUTOMATIC TRANSMISSION ONLY).
4. INSTALL GROUND CONNECTION. (a) Remove the original ground bolt. (b) Install the ground point onto the bolt. (c) Install the ground bolt. Torque: 9 Nm 5. CONNECT WIRING HARNESS. (a) Disconnect the 3 connectors of the engine ECU. (b) Connect the turbo charger control unit harness to the engine ECU. (c) Connect the 3 engine ECU connectors to the turbo charger control system harness. (d) Connect the grey connector of the interior harness to the engine room harness.
18.
CONTINUED
