Toyota TRD 3.4 5VZFE Supercharger Install Instructions

TRD 3.4-liter 4-l iter V6 V6 Super charger Ki Ki t Installation Instruc Instruct i ons 1996 - 2002 4Runner 1997 - 1998 T100 1997 - 2004 Tacoma 2000 - 2003 Tundra

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Supercharger Supercharger Kit Part Number:

PTR29-89020

IM PO POR RTANT WAR WARRANT RANTY Y INFO INFORMATION RMATION Dealers – Te Dealers Technic chnic ians: Failur e toto com plete pletely ly and properly fill ou t and m ail in your custom er’s Warranty Registration Registration Card m ay res resul t in pos posssible reduction reduction or com plete denial of futu re warranty claim s. Customer installed units: Failure to compl et etely ely and properly properly fill out and m ail in your Warranty Registration Registration Card m ay res resu lt in pos posssible reduction reduction or com ple plete te deni de ni al of future warranty claim s.

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1996 – 2002 4Runn er 1997 – 1998 T-100 1997 – 2004 Tacom a 2000 – 2003 Tundr a

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Descrip tion

1 1 1 1 1 1 1 1 1 1 1 1

Connection or Installation Location

Supercharger / Manifold Assembly Main Assembly – Bolts directly to Factory Manifold Supercharger Belt Replaces Factory Alternator Belt Ass emb ly, Dy nam ic Ten sion er Ass emb ly, Ten sion er Plate and Pull ey Installed on front of engine Dynamic Tensioner Plate Installed on front of engine Ass embly, Tensi on er Plate Ins tallat io n Hardw are Bolt, 10 X 1.25 X 73mm Flat Head Bolt hole A Bolt, 10 X 1.25 X 130mm Flat Head Bolt hole B Washer, 10mm Flat Bolt Hole C Wiring Loom Relocation Bracket Installed on front of engine Dipstick Relocation Bracket Installed on front of engine 6 X 1.0 X 12mm Bolt, Flange Head Dipstick Relocation Bracket

1 1 1 1 1 1 1 2 3 1 1 2 3

Kit, Literature 3.4L Installation Manual, Rev 8/10/08 Gasket, 3.4 S/C EO Sticker Warranty Card Warranty Certificate Mirror Hanger, S/C Noise Warning Sticker, TRD Logo Decal, Supercharger Template for cutting Front Cover Belt Routing Sticker Premium Fuel; Sticker Set, TRD S/C Emblems

Between Factory Throttle Body and TRD Supercharger Place underneath Hood Fill out and return to TRD Place in glove compartment Makes customer aware of Roots-type supercharger whine Place as desired on external surfaces of vehicle Place as desired Use to modify Factory Timing Belt Cover Under Hood Place 1 on or near fuel gauge and 1 inside of fuel filler door Place as desired

1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 2

Hose, Connector and Hardware Kit 1/8” Vacuum Plug 3/8” Vacuum Plug Vacuum Hose – ½”X 34” long Vacuum Hose – 1/8” X 14” long Wide Band Spring Clamp, Red Zip Tie, 3/16” X 7” Vacuum Adaptor Tee- 4WD only Valve, IAC Check Spacer, Manifold Support Bracket Bolt, 8 X 1.25 X 35mm Flange Head Bolt, 8 X 1.25 X 170mm Flange Head Bracket, Accelerator & Transmission Cable Bracket, Accelerator Cable Bracket, Throttle Cable Bolt, 6 X 1.0 X 12mm Flange Head

2001 and newer Tacoma only w/Drive by wire throttle body Intake Silencer Plug Connects Air Tube to Cam cover Connects Vacuum Throttle opener to Intake Manifold Secures Breather Hose at the 12mm Valve Cover Barb Retains Evaporative Canister Hose to Throttle Cable See Hose Routing Schematic Figure B Installed near IAC Valve Installed between manifold & factory support bracket, driver side Secure factory support bracket thru spacer to S/C Manifold Installed thru top of S/C to Factory Manifold Used on all models except 4WD M/T Tacoma Used on 4WD M/T Tacoma only 2001 & newer 4Runner only w/Drive by Wire Throttle Body Used to attach Throttle Cable Brackets to S/C Manifold

Tools Recommended Basic Tools

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Safety Tool s

Basic Metric Socket, Allen & Wrenches Special Tools Pencil & Paper for drawing schematics of Cable Routing ½” Masking tape for labeling hardware, parts, etc. 2” wide masking tape for covering intake manifold A clean Work Bench A Parts Tray Rags and or Shop Towels

Safety goggles ®

LocTite P/N 243 14mm Angles Flat Ratchet, Power Steering Adjuster bolt Scribe for marking Timing Belt Cover Coping saw for cutting Timing Belt Cover Toyota Repair Manual (1-800-622-2033)

Install ation Instructions for 3.4-liter V6 Supercharger Kit

Section 2: Removal Procedure A. Preparation for Removal of Stock Intake Manifol d

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Before you begin, TRD recomm ends that you th orough ly clean the engin e and engin e com partm ent. If you don ’t, grease buil dup on parts could becom e dislodged durin g the procedure an d fall in to the engin e.

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Make sure the engine has cooled fully before you begin.

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To helpyou later, we suggest you draw diagram s of your engine’s cable routin g before you disconnectanythin g. You can do the sam e for the vacuum hoses; however, som e of the vacuu m connections on you r stock m ani fold m ay not be the sam e as those on th e sup ercharger. To ensure the proper h ose conn ections, refer to the diagrams in the back of this man ual.

Figure 1

Th e TRD supercharger ki t has been designed to reuse m ost of the stock nu ts an d bolts. Therefore, as you r em ove them , keep them wi th their com ponents or label them for location. This will assur e a faster, easier in stallatio n.

B. Removal of Stock Intake Manifol d (fi gure 1) 1. Disconnect the battery groun d cable. 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 of the power steering an d th e air condi tioni ng com pressor drive belts (figure 2) . Thi s will ensure that th e belts will be returned to their origin al position s and that th ey will rotate in th e sam e direction. I f you reverse the direction of rotation, i t m ay cause the belts to fray.

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Figure 2

Install ation Instructions for 3.4-l iter V6 Supercharger Kit

3. If equipped, rem ove the gravel gu ard from beneath th e radiator (figure 3) . Th is wil l gi ve you access to the A/C belt adju ster. TIP: The gravel guard consists of two pieces but it’s much easier to install if you remove it as a one-pieceassembly.

4. Loosen the pinch nut in the center of the A/C compressor belt pull ey and loosen the adjuster bolt enou gh to loosen the belt (see arro w, figure 4) . 5. Usin g the angled flat ratchet, loosen the pinch nu t and adju ster bolt for the power steering pu m p. 6. Rem ove the two belts. 7. Loosen the alternator pivot bolt (top) , pinch n ut and adju sting bolt and rem ove the alternator belt. Duri ng th e installation procedure, it will be replaced with a belt supplied with the supercharger.

Figure 3

8. Loosen the air in take tube clam ps at the thr ottle body and disconnect the M ass Air Flow Sensor plu g. CAUTION: The air sensor (see poin ter, f i gur e 5) is fragile so becareful when working around it.

Figure 4

Figure 5 Page

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Installation Instructions for 3.4-liter V6 Supercharger Kit

9. Rem ove any conn ections from the air in take tube and rem ove the tube (fi gure 6) . 10. Som e trucks are equipped with on e or two Vacuu m Switched Valve ( VSV) assem bli es. To locate you rs, consul t th e appropria te diagram s on pages 20 through 23 . If the valve is m oun ted on the rear of the engine, it should be relocated to the firewall with the bracket supplied. 11. Note the tension an d adju stm ent of the throttle cable and th e transmi ssion throttle-pressure ( kickdown ) cable (if equipped with an au tom atic transmi ssion ). You will need to re-create these adjustments during the assembly procedure. To help you remem ber, look for the sm all m etal bead (th e stake stopper, auto m atic transm ission on ly) on the kickdown cable (see ar ro w, figure 7) . If the cable is properly adju sted, the bead shou ld be flush with the end of the cable’s rubber sheath (see arr ow, figure 8) .

Figure 6

Figure 7

Figure 8 Page

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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 the cable nu ts (figure 9) . Slide the cables from their br ackets and r em ove the cable ends from the throttl e-body levers. 13. Unplu g the throttle-position sensor conn ector (A) and th e IAC (I dle Air Control) valve conn ector (B) (see arr ows, figure 10 and diagram on page 23).

Figure 9

A B

Figure 10

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14. Rem ove vacuum lin es from the throttle body but don’t r emove the two coolant hoses (figure 11) . TIP: The coolant hoses have clamps ( see arr ows, fi gur e 12), the vacuum hoses do not.

15. Remove the throttlebody with attached coolant h oses and cru ise contr ol cabl e (if equ ipped) and set to the passenger’ s side (figure 12) . 16. At the dri ver’s side of th e eng in e, rem ove the diagn ostic plug from i ts m ountin g bracket (upper arrow, figure 13) and set it aside. Rem ove the boltand bracketthat hol dsthediagn ostic con nectortot hestock m anifold and save for reassem bly. Remove the ground wi re and m ove it to one side (lower arr ow, figure 13) .

Figure 11

17. Rem ove the vacuum hoses for th e power brak e, PCV and EVAP from their tubes on the upper man ifold.

Figure 12

Figure 13 Page

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18. A pre-2000 Tacom a or T-100 m ay be equipped with an EGR valve. To be sur e, look for th is tube (see arro w, figure 14) o n t h e drver’s-side exh aust man ifold. Remove the valve according to the prcedure on page 14. 19. Rem ove the bolt holdin g the man ifold to the intake cham ber stay (see arro w, figure 30) . Save the bolt. 20. Rem ove the nuts and bolts from the upper half of the in take man ifold an d set it aside (figure 15) . 21. Rem ove the 2 bolts and di sconnect the fuel-return lin e bracket (but don’t disconnect the fuel hose) from the driver’s side of the lower m anifol d and remove the bolt from the wire-loom bracket. Figure 14 22. Rem ove the bolts and n uts from the lower m ani fold. TIP: Thenuts at thefar 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 ani fold (figure 16) and save the factory nu ts, washers an d two short bo lts, as they wil l be reused. 24. In spect the gasket. If it is in good shape, reuse it; if n ot, replace it with a new one (part# 17176-62040). NOTE: The gasket between the surge tank and the manifold (figure 15) is interchangeable for useas the supercharger’s intake manifold gasket (see section B –2, page 11).

Figure 15

Figure 16 Page

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25. Tape over or cover th e eng in e ma ni fold por ts to keep out debris (figure 17) . 26. Usin g the tem plate suppli ed and a scribe or m arker, mark the top of the tim in g belt cover aroun d the tem plate (figure 18) . 27. Move any wires out of th e way and with a coping saw blade or flexible saw, cut alon g the scribe m ark (figure 19) and discard the cut-out piece. Thi s cutaway wi ll provide the clearance for the drive housing of the supercharger.

Figure 17

Figure 18

Figure 19 Page

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28. Attach th e plastic wi re loom s to the cut edge of the front cover (figure 20) . Th e igni tion wi res will go beneath th e supercharger drive hou sin g.

Section 3: Installati on Procedure A. Install ation of TRD Dynamic Belt Tensioner Assembly 1. Remove dipstick an d dipstick tube. 2. Unclip the wire loom from the factory bracket and install the TRDsuppli ed wire loom relocation bracket (see arro w, figure 21) . Use the existing n ut on the water pum p hou sin g’s upper stud. Torque to factory specifications and clip th e wire loom to the back of the TRD bracket.

Figure 20

3. In stall th e belt tensioner plate usin g the TRD flat h ead bolt ( 1 0 x 1 .2 5 x 73m m ) i n L o ca t i on A (figure 22) , do not full y tighten yet. NOTE: If the vehicle has been i n use, the holes (ArrowsA& B in figure 22) may need to becleaned out (i.e. tap).

4. Usin g the TRDsupplied bolt (10 x 1.25 x 130 ) (figure 22) , align the lower belt tension er mou ntin g bolt hole to Location B. NOTE: TRD recommends theuseof a thread locking liquid (such as Loctite 262) on the 10 x 1.25 x 73mm & 10 x 1.25 x 130 mm bolts in Locations A & B.

Figure 21

5. Torque the bolt i n Location A to 25 ft./lbs.

A

B

Hole C Figure 22 Page

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6. Rem ove the bolt in Location B. Set the alternator to m id-poin t adjustm ent on th e adjustable bracket (see figure 23) . Torque the pivot bolt (top) and pin ch nu t (arrow) to factory specification. 7. Place th e dynam ic ten sion er onto the m oun ting plate with th e belt behind the pull ey (figure 24). NOTE: Align the stud on backside of tensioner to small hole “C” in belt tensioner plate (figure 22).

8. Install the hex head bolt (rem oved in Step 5) th rough the tensioner in to the m ou nti ng pl ate and torque to 40 ft./lbs.

Figure 23

Figure 24

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B. Installati on of TRD Supercharger and Manifold Assembly 1. ( Skip this step for 2001 and newer 4Runner) Cut th e ho se leading to th e IAC valve conn ector at th e location shown, an d in sert the ki t’s one-way valve into the straight part of the h ose. The black end of the valve (see arrow, figure 25 and diagram on page 23) is closest to th e thr ottle body. IMPORTANT: The IAChose and the coolant hoses are similar in size. Don’t cut the wrong one. The coolant hoses have clamps, the IAC hose doesnot.

2. Rem ove the tape from the intake m anifol d and reinstall th e stock gasket.

Figure 25

3. Lower the supercharger and m anifol d into place m akin g sure t 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 e routed beneath the supercharger’s drive housing (see ar ro w, figure 26) . 4. When th e assembl y sits flat on th e engin e, put th e stock m ani fold brace (driver’s side) bolt and TRD spacer in first (see arrow, fi gure 27) and th en in stall th e stock nu ts on th e studs at each end of th e m anifold and hand tighten. Use M x mm Bo t 5. Install the TRD-supplied long m anifold bolt (8 x 1.25 x 170m m ) throu gh th e supercharger to the stock m ani fold followed by the two stock bolts. Alternating from one side to the other, torque the bolts and two nu ts to the specs provided in the Toyota Repair M anu al. Figure 26 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 thru it. The valve needs to be installed so that the flow goes into the engine.

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Figure 27


Supercharger Pulley

6. Place the drive belt over the water pum p pull ey, the crank shaft pull ey and th e alternator pull ey (figure 28) . Ma ke sure the belt is on th e correct sides of and pro perly seated i n th e grooves of each pulley. 7. To assist in belt in stallation , using a 3/ 8" l ong h andle ratchet (fi gure 29) , pull down in d irection of ar r ow to provide slack on belt. 8. Install the power steering and A/C belts according to the marks you m ade before rem oval ( see section 2 , figur e 2, page 2). 9. In stall th e TRD-suppl ied dipstick relocation bracket (see arr ow, fi gure 30) util izin g the factory bolt. Reinstall th e factory dipstick an d attach it to new bracket usin g the TRD-suppli ed bolt (6m m x 1.0 x 12m m ) . Torque both bolts to 10 ft./l bs.

Tensioner Pulley Water Pump Pulley

Alternator Pulley

Figure 28

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

Figure 29

Figure 30 Page

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C. Throttle Body and Air Tube Install ation

B

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

1. Using the gasket, OE Fasteners throttle body onto the supercharger’s man ifold.

A

, in stall the

IMPORTANT: Do not r euse the OE metal gasket (A, fi gur e 31) 1 2 lbs. on the throttle body. It will reduce boost output by 1 / Use the gasket supplied with the kit ( B, fi gur e 31) , and make sur e 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 bolt to the specs provided in the Toyota Shop Manual. Do not overtighten.

Figure 31

3. Install the throttle position sensor plu g, the coil plug (i f removed), and th e IAC valve conn ector. 4. Attach the PCV hose to the PCV valve on the passenger’s side of the engine. 5. Install the air inlet tube to the throttle body and Mass Air Flow Sensor an d reconn ect its hoses and tubes. Be careful not to dam age the sensor (figure 32) . 6. Install th e proper cable bracket to the top of the m ani fold. TRD supplies three throttle cable brackets. The bracket with only one U-shaped cable m oun t is to be used only on Tacoma 4WD m anu al-transm ission vehi cles. The bracket with two U-shaped cable m oun ts is to be used on all other m odels except 2001 and newer 4Ru n n ers. For 2001 and newer 4Run ners, use cable bracket num ber 00602-17620-080.

Figure 32

7. Rem ove the transm ission cable clam p from the m anifol d support. Clam p is no l onger needed. 8. Rem ovethethrottle cable/evaporativecanisterhose bracket and bolt f 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 s shown ( 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 d evaporative cani ster hose, and in stall the Zip Tys on the thr ottle cable and evaporative canister hose as show n (see arrows B, figur e 33) . NOTE: 2001 TACOMAWITH “DRIVE BYWIRE” THROTTLE BODY Thetwo 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. Page

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B

A B

Figure 33


9. Place the throttle and autom atic transm ission k ickdown cable ends in th eir origi nal th rottl e body levers. Refer to Step 11 in Section 2 on Page 4 and Figu re 8.

A B

10. Install th e transm ission k ickdown cable ( see arr ow A, figure 34) and th rottle cable (see arrow B, figure 34) i n thebracket. 11. Proper th rottle cable tension can be accom plished by viewing Figures 35 & 36. With a ligh t but firm pressure you wil l be able to hear a distinctive “ click” when pressin g down (see figure 35) . Release finger pressure and you shoul d hear an other “ click” as bracket m eets bracket (figure 36) . Figure 34

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

.080" - .125" Approx.

Figure 35

0.00" No gap

Figure 36 Page

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12. Install the diagnostic plug bracket and the ground con nector to the driver’s side of the sup ercharger. In stall the diagnostic plu g (see arrow A, figure 37) . 13. Install the fuel return lin e bracket to the driver’s side of the man ifold (see arrow B, figure 37) .

A

14. Usin g your diagram s, and those in the back of this m anu al, double check the routing of vacuum hoses, cables and brackets and correct any problem s (figure 38) . 15. Install th e gravel guard. 16. Attach th e groun d cable to th e battery. B

17. Apply the prem iu m -fuel stickers to the fuel gauge and fu el filler door. 18. Apply a TRD belt routing sticker and the Executive Order(EO) label tot h e un derside of the hood. Th e EO will alert state sm og in spectors that the TRD supercharger has been certified emissions legal in all 50 states.

Figure 37

19. The kit al so in cludes three “T RD” badges and th ree “ Supercharged” emblem s. They shou ld be applied to your tru ck’s front fenders and tailgate but, before you do, make sure the paint surface is clean and dry. Any dirt, gr ease or wax wil l cau se the badges to stick poorl y.

Figure 38

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D. Throttle Body and Air Tube Install ation for 2001and newer 4Runner only wi th Drive by Wire throttle system 1. Remove rubber plug (see arr ow A, figure 39) and hose ( see arro w B, figur e 39). Retain th e plug for reuse, but the hose is not used on the supercharger in stall . 2. Place the rubber plug on th e open air box n ipple ( see arr ow, figure 40) .

A B

3. The rubber plu g for the brake booster m oves to sam e location n ipple on supercharger hou sin g. 4. Th e rubber plug from the metal vacuu m tube at top rear of man ifold will m ove to the barb on th e throttle body m oun ting surface.

Figure 39

5. Rotate th e stock h eater h ose assem bly (see arro w, figure 41) located on th e firewall an d rotate approxi m ately 30 degrees up ward. Th is will provide proper clearan ce away from re-rou ted valve cover breather h ose.

Figure 40

Figure 41 Page

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Section 4: EGR Removal and Installation If your T acom a or T-100 is equipped with an Exh aust Gas Recircul ation (EGR) valve (see arrow, fi gure 42) , you wil l n eed to remove the valve from the stock in take man ifold an d reattach it to the TRD supercharger m anifol d. Here’s how:

A. Removal 1. Loosen the EGR pipe from the driver’s side exh aust m anifol d. Thi s will ease the rem oval and in stallation procedures (figure 42) . 2. Loosen or rem ove the clam p hol din g the pipe to the back of the engine. Figure 42

3. Rem ove the two nu ts hol ding the EGR pipe to the EGR valve and separate the two. 4. Remove the two n uts hol din g the valve and its gasket to the stud s on the intake m anifold. 5. Rem ove the EGR valve and gasket from the intak e m anifol d and set to on e side. If n ecessary, rem ove the EGR hose and vacuu m ho se but don’t disconnect the two water bypass ho ses. Th ey’re the on es with the sprin g clam ps.

B

A

B. Installation 1. Rem ove the EGR block-off pl ate from the two studs on the supercharger m ani fold an d using these nu ts and washers, install the EGR gasket and valve to the m ani fold and h and tigh ten (see arrow A, figure 43) . 2. With the superch arger bolted to the eng in e, attach th e EGR valve to the EGR pipe and hand tighten with th e original nu ts (see arr ow B, figur e 43) . 3. Tigh ten th e nu ts hol ding th e EGR pipe to the exh aust man ifold (figure 42) and torque them to the specs provided in the Toyota Repair Manu al. 4. Torque the EGR-pipe-to-EGR-valve nuts and the EGR-valve-tom ani fold nu ts to the specs provided in the Toyota Repair M anu al. 5. Install the pipe clam p to the stud on the back of the engi ne and tighten the nut.

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Figure 43


Supercharger I nstructi on FAQ’s 1. Would it be a good idea to install a fuel pressure regulator along wi th the supercharger? No. After extensive testin g, TRD ha s learned th at th e fuel system has sufficient capacity to deliver the additional fuel to m atch the additional air i ndu ced by the supercharger.

2 . I h a v e h e a r d o f s o m e i n c i d e n t s o f t he supercharger causing engine pinging because o 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 a solution for this issue. Th e Toyota Electronic Control Uni t’s (ECU) program constantly “ learns and adju sts.” Wh en the drivin g style chan ges— as when a supercharger is in stalled— the ECU will require a few hu ndred m iles to learn an d adju st for the difference. Durin g thi s period, 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 r ex 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 CU adjusts fuel enrichm ent an d ignition tim ing. Unless the “ pinging” conti nu es over a period o f sustain ed drivin g, thi s does not po se a problem. T he Boost-a-Pum p produ ct raises the voltage suppli ed to t 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 ’s theoretical output capacity and delivery pressure. The Toyota OE fuel pump has adequate delivery capacity, and the fuel pressure regulator is un changed when th e supercharger is in stalled. This m eans that th e system will still be regul ated at approxim ately 48-52 psi, so there’s no need for higher output.

3. What air fi lter does TRD recommend? A new factory air fil ter wi ll work, for best resul ts TRD recom m ends the use of our washable/reusable high flow air filters available at the nearest Toyota dealer or by callin g TRD direct at (800) 688-5912.

4. What is the added benefit if I also installed TRD headers and an exhaust system? Addition al power can be gained from headers and a perform ance exhaust system. At the time of this printing, TRD offers all stai n lesssteel -h ea der s an d ca t- back ex h au st system s for m ost vehicles equipp ed with the 5VZFE engine.

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5. There has been some confusion as to which vehicles the supercharger w orks best on. Please clari fy. Whi le the supercharger will fit the engin e, the Electronic Control Uni ts (ECUs) u sed in 1995 and 1996 T-100 and Tacom a trucks do not respond as well to superchargi ng as do the 1997 and later vehicles. For this reason, TRD does NOT recommend the supercharger for the 1995 and 1996 Tacom a and T -100 trucks.

6. I don’t see an EGR setup on my truck. How do I know i f I have one? Refer to figur es 14, 44 and 45 in th e instruction m anu al.

7. How wil l installi ng a supercharger affect my gas mil eage? During part-throttle driving, around town and highway cruise, for exam ple, the supercharger shou ld n ot noti ceably affect gas mileage. Overall fuel mileage decreases with increased full throttle operation, and decreases more when supercharged. Simply put, additional power requi res additional fuel and duri ng boosted, full -power operation, th e fuel m ileage will decrease m ore than when th e engin e is norm ally aspirated.

8. I would like to install the supercharger myself. Does it hurt the stock warranty or does the warranty stay for everything but the supercharger? Regardless of wh ether the sup ercharger is in stall ed by the Toyota dealer or by you, the Toyota New Car Warranty isun affected.If the su perchargeris in stalled atthedealershi p, thewarrantyonth e su perch arger is for either 5 years or the rem aini n g vehi cle powertrain warranty, (whichever com esfirst) .I f thesuperchar geris installed by other than a Toyota dealershi p, the warranty on the supercharger is for one year. Each supercharger k it i nclu des a warranty card, whi ch full y explains the details. After reading the warranty inform ation, please fill ou t the card and m ail it back to TRD .

9. Do I have to change my exhaust system? No, however u pgrading to TRD headers and a cat-back exhau st system is strongly recommended for best performance.


10. If I do choose to take it to a Toyota dealer to be installed, can you recommend one in my area? TRD’s website, www.trdusa.com, has a dealer locator function. If you prefer, please call TRD’s helplin e at (800) 688-5912, and we will be glad to assist you in locating a TRD stocking dealer.

11. How much boost should the TRD supercharger make? Is a small er pulley available for the supercharger, so that it might make more boost? The TRD supercharger comes with one pulley size only, designed to deliver approxi m ately 7 psi of boost pressure. Th e pul leysize, as youunderstand, affectsth edriveratio betweenth e supercharger and the engin e. In creasin gthe speedof thesupercharger relative t 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 e actual torqu eand poweroutput of the engin e. TRD has conducted hu ndreds of hour s of dynam om eter testing, and fou nd in som e cases that raisin g th e boost level m ay actual ly decrease engi ne perform an ce. Th e pull ey size, and boost level, of the superch arger ha ve been designed to achi eve the best m ix o f perform an ce, efficiency and overall reliabil ity. Chan ging the pull ey WILL void the warranty on the supercharger.

12. Does it matter if the transmission is manual or automatic? The supercharger will work properly regardless of transmission type.

13. Do I need to add a transmi ssion cooler i f I do not intend to do any towing? A tran smi ssion cooler provides added protection for your autom atic transmi ssion , regardless of your i ntended use. TRDstrongly recomm ends installing the transm ission cooler on an y vehi cle that m ay be used for towin g, especially i f a supercharger is installed.

14. Do I have to change the vehicle’s computer (ECU)? Do you suppose it’s possible to change out the 1995 or 1996 computer (ECU) with the ‘97 or ‘98 model? TRD does NOT recom m end using any com puter for your vehicle other than the one that i s made for the specific vehicle by Toyota. TRD offers no m odified or alternative compu ters, as the TRD supercharger ha s been design ed to be com patibl e with th e factory computer.

TRD does not recommend the addition of our Supercharger Kits to any 1994-1995 T100, Tacoma or 4Runner. The older vehicle engine management electroni cs does not lend itself to supercharging.

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Figure A Year Model

2001 and newer 4Runner 2WD

Notes:

Figure B Year Model

2001 and newer 4Runner 4WD

Notes:

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Figure C Year Model

2001 and newer Tacoma 2WD

Notes:

Figure D Year Model

Year Model

1997-2001 Tacoma 4WD 1996-2000 4Runner 4WD

Notes:

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Figure E Year Model

1997-1999 Tacoma 2WD, EGR

Notes:

Figure F Year Model

2001 Tundra V6

Notes:

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Figure G Year

1997-1998 Model T-100 2WD & 4WD Notes: P/S Valve Circuit not on all models. Installation requires an additional 5/16” “ T” -Fitting that is not included in the kit.

Figure H

One-Way Valve Install ation Diagram Notes:

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Toyota Racing Development www.trdusa.com

1.800.688.5912

Sym ptom

Possibl e Causes

Corrective Action

I dles r ou gh , “ pin g s” ( Tr ou ble Code PO171— Lean Code)

L ea n con di tio n — va cu u m lea k

Ch eck vacu u m lin e con n ection s for leaks an d crack ed en ds. Review factory service m anu al for proper factory vacuum routi ng. Review instructions for proper vacuum line routing. Check installation of the TRD throttle body gasket. If gasket is installed im properly, a vacuum leak will occur. Recheck torqu e on throttl e body bolts. Leak at manifold gasket. Recheck torque on intake manifold bolts.

Pin gs du rin g acceler ation

Low octan e fu el

Fil l tan k with PREMIUMFUEL.

Compu ter has yet to a dj u st to su per ch ar ger

Drive several hu ndred m iles in different driving m odes ( 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 eplacem ent procedures. Fuel pressure low. Follow factory diagnosis and replacement procedures. In jector(s) clogged. Follow factory repair/replacement procedures.

Low boost

Bel t sl ippi n g

Ch eck con diti on of bel t— oily, wor n , h igh m ileage.

Ai r fi lter di rty

Ch eck /r epl ace ai r f il ter . A di rty fi lter restr icts th e ai r i ntak e. T RDdyn o tests have shown that th e TRD air filter is am ong th e best on the m arket for flow and fi ltering char acteristics.

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 at full depression on th e gas pedal achieves full thr ottle opening at th e throttl e body. Check the supercharger bypass valve for proper operation .

M a kes a m o d er at el y l ou d n o ise u n der fu l l th r ottle— in tak e n oise

N or m a l su p er ch a rg er sou n d

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 s im possible with ou t som e n oise. Call TRD for fu rth er diagn osis.

R at tl in g a t i dl e— g oes a wa y at ju st above idle

N or m a l su p er ch a rg er sou n d

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 t 400 - 500 rpm above idle. Call TRD for fu r th er diagn osis.

Rattlin g above idle— gets louder with higher rpm or louder with m ore boost pressure

Drive hou sing bearing wear or backlash

Call TRDfor furth er diagnosis.

I dler pu lley bear in g w ea r o r ex c essi v e f r ee pl a y

Dia gn oseb yr em oving b el tf r o ms u perch arge r a n d r u n n in g e n gin e for l ess t h a n 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 properly li n e u p

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 e lever m ou n t brack et is for u se on Tacom a tru ck s with 4WD an d m an u al transm ission. Th ese vehicles have a slightl y different thr ottle arm . All other vehicles should use the two-cable mount. Manual transmission vehicles leave the transm ission cable m oun t empty. Use bracket 00602-17620-080 for 2001 and newer 4Runner.

Su p er ch a r ger b el t j u m p s across pu ll ey gr ooves

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 ten to specification s given , follow th e pr ocedu re in th e factory m an u al.

Dam aged pu lleys

Be su re th at th e pu ll eys all r un tru e— n o eccen tr icity.

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-tig hten to specifications given, follow the procedures in the factory m anu al.

Su p er c h a r ger b el t l ea v es g r e y/ b l a ck powder on drive housing and oth er areas

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.

Supercharger appears to leak oil from drive h ou sin g

Front seal not fully brok en in

No im m ediate corrective action. Seal should be fully m ated to pulley after 2000 m iles. I f leak in g con tin u es, con tact TRD.

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IM PORTANT WARRANTY INFORMATION Dealers – Technic ians: Failure to com pletely and properly fill ou t and m ail i n you r custom er’s Warranty Registration Card m ay resul t in possible reduction or com plete denial of futur e warranty claim s. Customer installed units: Failure to com pletely and properly fill out and m ail in your Warranty Registration Card m ay resu lt in possible reduction or com plete denial of future warranty claim s.

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Toyota TRD 3.4 5VZFE Supercharger Install Instructions

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