Toyota pmn manual

1 INSTALLATION INSTRUCTION MANUAL ISS REVISION RECORD DA TE REVR. 0 NEW Oct. 05 1.0 1 Revision Oct. 05 1.1 ATTENTION Read this installation instruct ion 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 qu[...]

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3 T ABLE OF CONTENTS TABLE OF CONTENTS ................ ... ... ... ................. ... ... ... ................ .... ... ... ................ ... .... ... ...... .................... ........... 3 PRECAUTIONS ................ ................ ................ ................ ................. ................... .............. .. ..............[...]

4 10. Intercooler preparation .......... .................... ................... ................ .................... .............. ........ ................ 40 1. Install lower bracke t. ........... ................. ................ ................ ................ ................ ......... .................... ... 40 2. Install upper bracke[...]

5 17. Install interior co mpartment ............... ....................... .......................... ...................... ........ ..................... 61 1. Install control-unit assembly. (manual transmission only) ...... ................... .................... ................ ..... .6 1 2. Remove automatic transm ission control-unit (autom[...]

6 PRECAUTIONS PLEASE READ THOROUGHL Y THESE PRECAUTION S BEFORE INST ALLING THE CHARGER KIT Do not pinch the rear wring or harness in the tightened part. When passing the wires through the dashb oard or other panels, use a grommet to ensure wate rproofing. Protect the wiring with tape w hen it is passed through a hole. When disconnecting a connecto[...]

7 PREP ARA TION 1. SST (Special Service T ools) 2. Lubricant s / Liquids 1 09032-00100 Oil pan remo ver 2 09228-06501 Oil filter wrench 3 09816-30010 Oil pressure switch wrench 4 AM 300-38300 Jack nut tool Engine Coolant Ethylene-glycol base Engine oil API grade SH energy- conserving II or SJ energy-conserving or ILSAC multigrade engine oil. Refer [...]

8 VEHICLE LIFT LOCA TIONS In this manual, a plate type or swin g arm lif t is recommended. See the d escription below for det ails of the supporting and att achment 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 atta chment lower ends (A,B). (c) Align the at tachm[...]

9 PA R T S 1. Location Numbers with a cha r act er (Ex. 14 -1 ) in “P ARTS LOCA TION” corresponde nt to numbers in the text and the illustration in “INST ALLA TION PROCEDURES” as well as “No.” in “P ARTS LIST”. 1.1. T URBO CHARGER 17-1 16-2 16-2 17-4 16-3 18-2 18-1 18-3 18-3 3-1 13-2 13-3 13-1 13-3 16-1 14-8 14-3 14-3 14-4 17-7 16-4[...]

10 1.2. HEAT SHIELD 4-1 4-1 10-3 10-3 10-6 10-6 10-6 10-6 10-1 10-4 10-4 10-4 10-5 10-5 10-5 10-8 10-8 4-4 10-2 4-1[...]

11 1.3. EXHAUST MANIFOLD 4-2 4-1 4-3 4-3 3-7 9-3 9-3 9-3 9-3 9-3 9-2 9-1 4-1 4-1[...]

12 1.4. INTERCOOLER 8-6 8-1 8-5 8-3 8-5 6-4 6-2 6-4 6-1 6-5 8-4 7-7 7-2 7-5 7-7 7-3 7-6 7-7 7-4 7-8 7-6 7-5 6-4 7-1 6-3 6-4 8-2 8-4[...]

13 1.5. AIR INT AKE 25-1 25-1 2-2 1-1 25-2 25-4 2-9 2-11 2-10 2-5 12-1 12-3 2-10 2-10 12-4 2-6 2-7 2-7 2-8 12-4 17-6 2-1 2-4 1-2 2-1 12-1 25-3 25-3[...]

14 1.6. OIL FILTER 13-2 13-3 13-3 13-1 13-4 13-4 26-7 15-2 15-3 15-3 15-1 13-1[...]

15 1.7. OIL PAN AND BRACKET S 27-1 14-2 14-7 14-1 14-6 14-5 14-6 19-1 20-3 20-1 20-2 5-1 5-4 5-5 5-3 5-2 5-6 5-5 19-2[...]

16 1.8. ELECTRIC COMPONENT S 24-8 24-8 24-8 24-3 23-9 2x 23-8 15x 23-4 24-7 24-2 24-9 23-5 23-2 23-1 23-6 35-1 24-6 24-9 23-5 24-6 24-7 24-2 15A[...]

17 1.9. COOLING FAN 22-3 22-2 22-3 22-3 22-3 22-4 22-4 22-4 22-4 23-3 24-10 24-4 24-5 24-11 24-11 24-1 22-1 24-10[...]

18 1.10. T EMPLATES 27-2 27-4 21-1 21-3 21-2 27-1 27-5 21-5 3x 21-5 3x 21-4 3x 21-4 3x 27-3 2-12 Cutting lines for hose[...]

19 1.1 1. HEAT INSULATION, STICKERS AN D SPARKPLUGS 26-1 11-1 26-2 11-2 11-2 11-2 11-2[...]

20 2. Part s List No. P ART NAME QTY P ART No. REF 1.0 KIT, AIRBOX 1 AM300-32400 1-1 Bellow with spring cla mps 1 AM183-17000 1-2 Airfilter , sport 1 AM181-50000 2.0 KIT, INTAKE TURBO 1 AM300-32500 2-1 Hose clamp 50-7 0 2 AM901-17000 2-2 Pipe Airbox turbo 1 AM182-63000 2-3 Bracket, pipe a irbox-turbo 1 AM300- 25500 2-4 Hose, int ake T urbo 1 AM300-[...]

21 7.0 KIT, INTERCOOLER 1 AM300-33000 7-1 Intercooler 1 AM181-82000 7-2 Bracket, intercooler , No.1 1 AM300-27600 7-3 Bracket, intercooler , No.2 1 AM300-27700 7-4 Bracket, intercooler , No.3 1 AM300-27800 7-5 Cushion M8 2 AM300-27900 7-6 Bolt, hex head M 8X12X1.25 1 9151 1-B0812 7-7 Nut, hex head M8X1.25 3 90179-08206 7-8 Bolt, hex headM10X20X1.2 [...]

22 14-4 Pipe, oil runback 1 AM869-79000 14-5 Hose, connection to oil p an 1 AM869-80000 14-6 Hose clamp 16-25 2 AM300-27100 14-7 Gasket 2 90430-12031 14-8 Seal ring, oil runback pipe 1 AM902-1 100 0 15.0 KIT, OIL PRESSURE SWITCH 1 AM300-33800 15-1 Extension, oil pressure switch No.1 1 AM300-26300 15-2 Extension, oil pressure switch No.2 1 AM300-264[...]

23 23-3 Sensor , T emperature 1 AM300-30400 23-4 Power Control unit 1 AM300-310 00 23-5 Relay 2 AM300-31900 23-6 Fuse, 15 Ampere 1 AM300-34600 23-7 Arm a F lex 3 AM199-0 7 000 23-8 T ie Wrap 15 AM199-06000 23-9 T ie W ra p with socket 3 AM300-37200 24.0 KIT, FIXING, ELECTRONIC 1 AM300-30800 24-1 Bracket, Sensor , T emperature 1 AM300-30900 24-2 Bol[...]

24 3. Specified torque Part tightened Torque specification Nm kgcm f t.lbf Harness fixation clamp 3 30 2.2 Oil return adapter 45 460 33 Oil change plug 37 370 27 Air guide brac ket 5 50 3.7 Cooling-fan 6 6 0 4.4 T emperature sensor bracket 10 100 7.2 T emperature sensor 20 200 15 V acuum hose ada pter 25 255 18 VSV 9 90 6.6 Heat shield catalyser 6 [...]

25 Exhaust pipe onto turbo 16 160 1 1.5 Oil return pipe 20 200 15 Ground bolt 9 90 6.6 Cooling fan cover 6 60 4.4 Lambda sensor No. 1 44 450 32 Exhaust manifold heat shield 20 200 15 Lambda sensor No. 2 44 440 32 S park plugs 25 250 17.9 Ignition coils 9 90 6.6 Control-unit asse mbly (manual) 13 130 9.3 Control-unit assembly (automatic) 13 130 9.3 [...]

26 INST ALLA TION PROCEDURES 1. Introduction 1.1. SI UNIT. The UNITS given in th is manual are primar ily expressed ac cording to the SI (international System of Unit s), and alternately expressed in the metric sy stem and in th e English system . 1.2. CAUTION * NOTICE * HINT. CAUTION: There is a possibility of injury to you or other people. Be sur[...]

27 1.5. AIR HOSE AND CLAMP. NOTICE: – Follow the inst ructions below . Otherwise the hose may come off or intake air may leak, disabling driving due to engine stop. – Wrapping the hose clamp too tight ly ma y damage the part or related parts. 1.6. OIL AND COOLANT. Reuse the oil and coolant if it is judged possible from their condition. Paint ma[...]

28 2. Part s to be removed (see workshop manual for detailed instructions) U[...]

29 U U C ONTINUED[...]

30 3. V ehicle prep aration 1. REMOVE CARBON CANISTER . (a) Remove the clamp of the vacuum hose. R : Clamp (b) Disconnect the vacuum hoses f rom the carbon canister . (c) Remove the carbon cani ster from its bracket by sliding it upwards. R : Carbon canister 2. REMOVE HARNESS CLAMPS. (a) Cut the harness clamp (A) fr om the harness. U : Harness clam[...]

31 3. HOLE PREPARATION. (a) Drill the hole out to 1 1.2 mm. (b) Remove burrs and protect the hole with anti-cor rosion 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) 4. HARNESS FIXATION. (a) Mount the harness clamp onto the vehi cle harness. K : Harness clamp. (20-1) (b) [...]

32 4. Airfilter box heat shield prep aration 1. PREPARATION HEAT SHIELD. (a) Mark the position where to cut by using the template. K : T emplate (27-2) (b) Remove the marked p ar t, use an air driven saw or plate cuttin g too l. (c) Rem ov e sha r p ed ge s an d ins tall protection strip. K : Protection strip.(2 -1 2) K[...]

33 5. Oil-sump prep aration 1. INSTALL OIL RETURN ADAPTER . (a) Mark the position of the oil retu rn hose adap ter . (b) Punch-mark the drilling po sition.(s pot-weld position) (c) Pre-drill a 4 mm hole. (d) Pre-drill to 6.5 mm (e) Drill the hole out to 12mm. (f) Remov e burrs. (g) Install the oil return adapter with the nut and copper gasket and L[...]

34 6. Underbody protection prep aration 1. UNDERCOVER PREPARATION. (a) Rem ove the 10 pop-rivets from the under cover . (b) Remove from the bottom side (engine side) the pla stic reinforcemen t ou t of th e so un d ins ula tio n. NOTICE: Before removing the p lastic reinforc ement cut it with scissors. (c) Fix t he template t o the underc over with[...]

35 (j) Place the undercover on the floor (eng ine side facing down) (k) Rem ove drain p lug cover . (l) Prepa re the template . K : T emplate (27-1) (m) Fix the template onto the undercover with ta pe. (n) Mark the po sitio n wh er e to cut w ith a marker . (o) Mark the 6 hole positions into the undercover . (p) Rem ov e the t em p lat e. (q) Pre d[...]

36 (t) Install the aluminum br acket-spoiler onto the undercover with 3 aluminum jack nuts usi ng the jack nut tool.(SST AM300-3 8300) K : Bracket spoiler ( 21-1) K : Aluminum jack nut s (3 pcs.) (21-4) K : Jack nut tool (26-8) (u) Install the aluminum bracke t onto the undercover with 3 aluminum jack nuts using the jack nut to ol.(SST AM300-38300)[...]

37 7. Engine cover prep aration 1. ENGINE COVER PREPARATION. (a) Mark the po sitio n wh er e to cut. Use template 27-3 (b) Remove the marked p art, use an air driven saw . (c) Remove sharp edg es K : T emplate (27-3)[...]

38 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 bolt s and nut s. K : Bolt (4 pcs.) (22-3) K : Nut (4 pcs.) (22-4) T orque 6 Nm NOTICE: Ensure that the harness connect ion is facing the right direction. 2. INSTALL BRACKET TO COVER .[...]

39 9. Inlet pipe prep aration 1. INSTALL VACUUM HOSE ADAPTER . (a) Put Loctite 270 on the hose adapter . (b) Install the hose adapter into the inlet pipe. K : V acuum hose adapter (2-5) K : Inlet pipe (2-2 ) T orque: 25 Nm 2. PREPARATION OF VSV . (a) Mark the VSV bracket for drilling (b) Drill a 6.5 mm hole into the VSV bracket. R : VSV 3. INSTALL [...]

40 10. Intercooler prep aration 1. INSTALL LOWER BRACKET. (a) Install the rubb er mounting onto the intercooler with Loctite 243 and hand tighten. 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 In tercooler No. 1 (7-2). K : Nut (7-7) 2. INSTALL UPPER BRAC[...]

41 1 1. Pre-cat alyser heat shield prep aration 1. INSTALL PRE-CAT ALYSER HEAT SHIELD. (a) Install the heat shield with th e 2 clamps and 4 bolt s onto the ca talyser . K : Catalyser (10-1) K : Heat insulation No. 2 (10-2) K : Bolts (4 pcs.) (10- 6) K : Bracket (2 pcs.) (10- 3) T orque: 6 Nm NOTICE: Ensure clearance between t he clamp and the exhau[...]

42 12. T urbo control system preparation 1. T URBO CONTROL SYSTEM PREPARATION. (a) Install the powe r control-unit onto the bracke t 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) T orque: 8 Nm (b) Install the relays onto the bracket using 2 bolt s and 2 n[...]

43 13. T urbo preparation 1. T URBO PROTECTION. CAUTION: Cover all the inlet and outlet holes with protective t ape to avoid p arts from falling in. 2. REMOVE PLATE WITH PRESSURE ACTUATOR . (a) Remove the pressure actuator br acket by removing the clip and 2 bolt s. R : Clip R : Bolt (2 pcs.) R : Pressure actu ator . K : T urbo charge r (3-1) CAUTI[...]

44 5. INST ALL WATER OUTLET HOSE. (a) Install the outlet hose onto the outlet adapter . K : W ater outlet hose (17-1) T orque: 14 Nm NOTICE: Ensure that the connection is pointing into the right dire ction (in line with exhaust manifold co nnection) 6. INSTALL WATER INLET TUBE. (a) Install the water inlet tube on to the water inlet adapter . K : W [...]

45 9. INSTALL PRESSURE ACTUATOR HOSE. (a) Insert the pressure hose into the heat protection hose K : Pressure ho se (18-2) K : Hose Heat protection (18-1) (b) Install the pressure hose with the 2 clamps. K : Clamp (2 pcs.) (18-3) T orque: 2 Nm K K K K[...]

46 14. Inst allation engine comp artment 1. INSTALL EXHAUST MANIFOLD GASKET. (a) Place the new gasket onto the cylinder head studs. K : Gasket (9-2 ) 2. INSTALL EXHAUST MANIFOLD. (a) Install the exhaust manifo ld onto the cylinder head using the 5 nut s. K : Nuts (5 pcs.) (9 -3 ) K : Exhaust manifold (9-1) T orque: 37 Nm 3. POSITION T URBO CHARGER.[...]

47 5. INSTALL T URBO CHARGER BRAC KET. (a) Install the bracket with short bolt and washer to the engine (hand tighten) . K : Bolt (5-4) K : W asher (5-5) K : Bracket (5 -2 ) (b) Install th e bracket with lo ng bolt, washer and spacer to the T urbo charger (h and tighten). K : Bolt (5-3) K : W asher (5-5) K : Bush (5-6) 6. TIGHTENING T URBO CHARGER [...]

48 (f) Install hose on engine side with a clamp. R : Clamp T orque: 3 Nm 8. INSTALL WATER OUTLET CONNECTIONS. (a) Install the clamp s on the water outlet hose. K : W ater outlet hose (17-2) K : Hose clamp (2 pcs.) (17-3) T orque: 3 Nm (b) Install the water outlet hose between the T urbo charger water tube and the en gine water connection. NOTICE: E[...]

49 15. Inst allation engine comp artment lower 1. APPLY LIQUID GAS K ET TO OIL PAN. (a) Apply the liquid gasket onto the clean sump surface. NOTICE: Liquid gasket 0 8826-00080 2. INSTALL OIL P AN. (a) Within 3 minutes af ter applying the liquid gasket inst all the oil-sump onto the engine using the 14 bolt s and 2 nuts. R : Bolt (14 pcs.) R : Nut ([...]

50 5. INSTALL OIL PRESSURE SWITCH. (a) Install the oil pressure switch into the ad ap ter using Loctite 243. Use SST 09816-30010 R : Pressure switch T orque: 13 Nm (b) Connect the oil pre ssure switch connector to the pressure switch. NOTICE: T urn oil filter until the o-rings touches the flange. T u rn oil-filter 270 ° by hand. 6. INST ALL INT ER[...]

51 8. INSTALL OIL PRESSURE TUBE. (a) Install the oil pressure tu be onto the inlet pipe using the clamps. K : Clamp (2 pcs.) (13-4) 9. INSTALL INTERCOO LER OUTLET PIPE. (a) Position intercooler outlet pipe, hose and 2 hose clamps. K : intercooler outlet pipe (8-1) K : Hose interco oler side (8-2 ) K : Clamp (2 pcs.) (8-4) (b) Tighten outer hose cla[...]

52 (h) T ighten the Intercooler fixation bolts. T orque: 1. Bolt 16 Nm 2. Bolt 16 Nm 3. Nut 12 Nm 4. Nut 12 Nm 5. Nut 12 Nm 6. Bolt 12 Nm NOTICE: When applying the correct torque to the fixation b olts ensure the correct positioning of the Intercooler and clearance from surroun ding pa rts . (i) T ighten the inne r clamp of the inl et pipe T orque:[...]

53 16. Inst allation engine comp artment upper 1. INSTALL TURBO INLET PIPE. (a) Position the turbo inlet p ipe, hose and 2 clamps. K : Pipe, Airbox turbo (2 -2) K : Hose (2-4) K : Clamp (2 pcs.) (2-1) (b) T ighten outer hose clamp on turb o charger side. (c) Pull inlet pipe 5 mm out of the hose and hand tighten inner clamp. 2. INSTALL TURBO INLET P[...]

54 K Cutting lines for hose R K K K R K (d) Wrap th e T -junction with the anti-rattle foam. K : Anti-rattle foam (25-4). 5. MODIFY ENGIN E VENTILATION HOSE. (a) Modify the ve nt ilat ion hose as indicate d on the template. K : T emplate (27-5) 6. INSTALL ENGINE VEN TILATION HOSE O NTO ENGINE. (a) Install th e engine ventilation hose with the hose [...]

55 8. INSTALL VSV CONNECTIONS. (a) Install the vacuum hose 1 onto the VSV . 9. INSTALL AIR FILTER . (a) Remove the air filter from the air filter box. U : Air filter . (b) Install the high perfor mance ai r 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 fi lte r bo[...]

56 12. INST ALL EXHAUST PIPE PRE-CAT ALYSER . (a) Position the exhaust pipe next to the turbo outlet side. K : Exhaust pipe pre cat alyser (10-1) (b) Install the exhaust pipe o nto the turbo charger using the locking plate and bolt s.(handtigh ten) K : Locking plate No. 2 (4-4) K : Bolt (3 pcs.) (4-1) 13. INST ALL EXHAUST PIPE BRACKET. (a) Remove t[...]

57 15. INST ALL OIL RETURN HOSE. (a) Install the oil return hose onto the oil r etur n pipe and oil pan adap te r using 2 clamps. K : Clamp (2 pcs.) (14-6) K : Oil return hose (14- 5) 16. INSTALL WIRING HARNESS. (a) Insert the 15A fuse into the wiring harnesss fuse- socket. K : 15A Fuse (23-6) (b) Insert the vacuum hose into the grommet. Ensure tha[...]

58 (j) Route th e harness bran ch with the ground c onnection towards the original ground connection bolt. (k) Install the ground con nection. T orque: 9 Nm (l) Route the harness towa rds the bonnet hinge and follow the original vehicle harness. NOTICE: Ensure that there is enough harness slack to avoid ha rness damage due to engine movement. Ensur[...]

59 18. INSTALL LAMBDA SENSOR NO. 1 (a) Install the lambda sensor into the exhaust manifold. R : Lambda sens or . T orque: 44 Nm 19. INST ALL EXHAUST MANIFOLD HEAT SHIELD. (a) Install the exhaust manifold heat shie ld onto the manifold using the 4 bolt s . K : Heat insulation No. 1 (1 1-1) K : Bolt (4 pc s.) (1 1-2) T orque: 20 Nm (b) Connect the la[...]

60 (b) Install the lambda sensor ha rness with the clip into the bracket. K : Clip (19-1) 21. SP ARK PLUG EXCHANGE (a) Remove the 4 bolts of th e coils. R : Bolt s (4 pcs.) (b) Remove the ignition coils. (c) Remove the sp ark plugs. (d) Install new sp a rk plugs. K : S park plug (SK20R1 1-iridium) (26-2) T orque 25 Nm (e) Install the igniti on coil[...]

61 17. Inst all interior compartment 1. INSTALL CONTROL-UNIT ASSEMBLY . (MANUAL TRANSMISSION ONLY) (a) Install the control-unit asse mbly onto the studs using 3 nuts. K : Nut (3 pcs.) (24-8) T orque: 13 Nm 2. REMOVE AUTOMATIC TRANSMISSION CONTROL-UNIT (AUTOM ATIC TRANSMISSION ONLY). (a) Remove the 3 nuts. (b) Rem ov e the con tr ol- un it an d pu t[...]

62 4. INSTALL GROUND CONNECTION. (a) Remove the origina l ground bolt. (b) Install the ground p oint onto the bolt. (c) Install the ground b olt. T orque: 9 Nm 5. CONNECT WIRING HARNES S. (a) Disconnect the 3 connectors of the engine ECU. (b) Con nec t th e tur b o cha r ge r cont r ol unit ha rn e ss to th e engine ECU. (c) Connect the 3 engine EC[...]

63 18. Part s to be inst alled (see works hop manual for detailed instructions) K 20-4[...]

64 C ONTINUED[...]