Toyota 1ZZ-FTE- Manuals

Page 3 - TABLE OF CONTENTS; PRECAUTIONS

3 TABLE OF CONTENTS TABLE OF CONTENTS ............................................................................................................................................ 3 PRECAUTIONS ..............................................................................................................

Page 6 - Protect the car with fender covers and so on.; OK

6 PRECAUTIONS PLEASE READ THOROUGHLY THESE PRECAUTIONS BEFORE INSTALLING THE CHARGER KIT Do not pinch the rear wring or harness in the tightenedpart. When passing the wires through the dashboard or otherpanels, use a grommet to ensure waterproofing.Protect the wiring with tape when it is passed thro...

Page 7 - PREPARATION

7 PREPARATION 1. SST (Special Service Tools) 2. Lubricants / Liquids 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 Engine Coolant Ethylene-glycol base Engine oil API grade SH energy-conserving II or SJ energy-conse...

Page 8 - VEHICLE LIFT LOCATIONS; supporting and attachment positions.; (b) Align the cushion gum ends of the plate with; Swing arm type lift:

8 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 attachmen...

Page 9 - PARTS; Location

9 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. TURBO 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 ...

Page 20 - Parts List; PART NAME

20 2. Parts List No. PART NAME QTY PART No. REF 1.0 KIT, AIRBOX 1 AM300-32400 1-1 Bellow with spring clamps 1 AM183-17000 1-2 Airfilter, sport 1 AM181-50000 2.0 KIT, INTAKE TURBO 1 AM300-32500 2-1 Hose clamp 50-70 2 AM901-17000 2-2 Pipe Airbox turbo 1 AM182-63000 2-3 Bracket, pipe airbox-turbo 1 AM3...

Page 21 - KIT, EXHAUST MANIFOLD

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 M8X12X1.25 1 91511-B0812 7-7 Nut, hex head M8X1.2...

Page 24 - Specified torque; Part tightened

24 3. Specified torque Part tightened Torque specification Nm kgcm ft.lbf Harness fixation clamp 3 30 2.2 Oil return adapter 45 460 33 Oil change plug 37 370 27 Air guide bracket 5 50 3.7 Cooling-fan 6 60 4.4 Temperature sensor bracket 10 100 7.2 Temperature sensor 20 200 15 Vacuum hose adapter 25 2...

Page 26 - INSTALLATION PROCEDURES; Introduction; (b) The paint mark on the water hose is the reference for

26 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...

Page 27 - driving due to engine stop.; (a) The paint mark on the air hose is the reference for positioning.

27 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. 1.6. OIL AND COOLANT. Reuse the oil and coolant if it is judg...

Page 29 - ONTINUED

Page 30 - Vehicle preparation; (b) Disconnect the vacuum hoses from the carbon

30 3. Vehicle preparation 1. REMOVE CARBON CANISTER. (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 2. REMOVE HARNESS CLAMPS. (a) Cut the harness c...

Page 31 - (b) Mount the clamp with 1 bolt and bracket into the jack; NOTICE: Ensure that all harness and vehicle

31 3. HOLE PREPARATION. (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) 4. HARNESS FIXATION. (a) Mount the harness clamp onto the ve...

Page 32 - Airfilter box heat shield preparation

32 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.(2-...

Page 33 - NOTICE: Check if the gasket contact surface is

33 5. Oil-sump preparation 1. INSTALL OIL RETURN ADAPTER. (a) Mark the position of the oil return hose adapter.(b) Punch-mark the drilling position.(spot-weld position)(c) Pre-drill a 4 mm hole.(d) Pre-drill to 6.5 mm(e) Drill the hole out to 12mm.(f) Remove burrs. (g) Install the oil return adapter...

Page 34 - Underbody protection preparation; reinforcement out of the sound insulation.; NOTICE: Before removing the plastic reinforcement

34 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...

Page 35 - (s) Cut the marked position out of the undercover with a

35 (j) Place the undercover on the floor (engine side facing down) (k) Remove drain plug cover. (l) Prepare the template. K : Template (27-1) (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) Remo...

Page 37 - Engine cover preparation

37 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.(c) Remove sharp edges K : Template (27-3)

Page 38 - Cooling fan preparation; Torque 6 Nm; NOTICE: Ensure that the harness connection is; (a) Install temperature sensor bracket to cover

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 bolts and nuts. K : Bolt (4 pcs.) (22-3) K : Nut (4 pcs.) (22-4) Torque 6 Nm NOTICE: Ensure that the harness connection is facing the r...

Page 39 - Inlet pipe preparation

39 9. Inlet pipe preparation 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 2. PREPARATION OF VSV. (a) Mark the VSV bracket for drilling(b) Drill a 6.5 mm hole...

Page 40 - Intercooler preparation; (a) Install the rubber mounting onto the intercooler with

40 10. Intercooler preparation 1. INSTALL LOWER BRACKET. (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...

Page 41 - Pre-catalyser heat shield preparation; (a) Install the heat shield with the 2 clamps and 4 bolts; NOTICE: Ensure clearance between the clamp and

41 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 NOTICE: Ensure cle...

Page 42 - Turbo control system preparation; the 2 bolts and 2 nuts.

42 12. Turbo control system preparation 1. TURBO CONTROL SYSTEM PREPARATION. (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 r...

Page 43 - Turbo preparation; CAUTION: Cover all the inlet and outlet holes with; (a) Remove the pressure actuator bracket by removing; CAUTION: Close the inlet hole with tape to avoid

43 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. (a) Remove the pressure actuator bracket by removing the clip and 2 bolts. R : Clip R : Bolt (2 pcs.) R : Pressure ...

Page 44 - (a) Install the water inlet tube onto the water inlet adapter.; NOTICE: Ensure that the water inlet tube is; (a) Install the oil pressure tube with the screw and 2; NOTICE: Ensure that the connection is pointing

44 5. INSTALL WATER OUTLET HOSE. (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...

Page 45 - (a) Insert the pressure hose into the heat protection hose

45 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.) (18-3) Torque: 2 Nm K K K K

Page 46 - Installation engine compartment; (a) Install the exhaust manifold onto the cylinder head; NOTICE: The embossed side of the gasket should

46 14. Installation engine compartment 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 manifold onto the cylinder head using the 5 nuts. K : Nuts (5 pcs.) (9-3) K : Exhaust manifold (9-1)...

Page 47 - NOTICE: Some coolant will flow out of the cooling; stainless steel wire to fit.; NOTICE: Ensure that the clamp is covered by the

47 5. INSTALL TURBO CHARGER BRACKET. (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 : B...

Page 48 - NOTICE: ENSURE THAT THE CLAMP MECHANISM; (a) Install the blind cap on the throttle body housing with a

48 (f) Install hose on engine side with a clamp. R : Clamp Torque: 3 Nm 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 tub...

Page 49 - Installation engine compartment lower; (a) Within 3 minutes after applying the liquid gasket install; INSTALL OIL PRESSURE SWITCH EXTENSION.; : Oil pressure switch; INSTALL OIL PRESSURE SWITCH EXTENSION

49 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. (a) Within 3 minutes after applying the liquid gasket install the oil-sump onto the engine using the 14 bolts...

Page 52 - NOTICE: When applying the correct torque to the; (i) Tighten the inner clamp of the inlet pipe

52 (h) Tighten the Intercooler fixation bolts. Torque: 1. Bolt 16 Nm 2. Bolt 16 Nm3. Nut 12 Nm4. Nut 12 Nm5. Nut 12 Nm6. Bolt 12 Nm NOTICE: When applying the correct torque to the fixation bolts ensure the correct positioning of the Intercooler and clearance from surrounding parts. (i) Tighten the i...

Page 53 - Installation engine compartment upper; (a) Install the bracket with the 2 bolts onto the inlet pipe.; INSTALL WATER HOSE CLAMP; (a) Install the water hose with the clamp to the turbo inlet

53 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 ti...

Page 54 - (a) Modify the ventilation hose as indicated on the; (a) Install the engine ventilation hose with the hose clamp; INSTALL ENGINE VENTILATION HOSE ONTO; (a) Install the ventilation hose onto the turbo inlet pipe

54 K Cutting lines f or hose R K K K R K (d) Wrap the T-junction with the anti-rattle foam. K : Anti-rattle foam (25-4). 5. MODIFY ENGINE VENTILATION HOSE. (a) Modify the ventilation hose as indicated on the template. K : Template (27-5) 6. INSTALL ENGINE VENTILATION HOSE ONTO ENGINE. (a) Install th...

Page 55 - INSTALL AIR FILTER BOX COVER

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 performance air filter into the air filter box. K : Air filter, sport (1-2) 10. PREPARE AIR FILTER BOX COVER. (a) ...

Page 56 - (b) Install the exhaust pipe onto the turbo charger using; NOTICE: Temporarily install a bolt onto the bracket; (d) Bend the locking plates against the bolt heads to; CAUTION: Move to the right to have maximum

56 12. INSTALL EXHAUST PIPE PRE-CATALYSER. (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) 13. ...

Page 58 - NOTICE: Ensure that there is enough harness

58 (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 h...

Page 59 - INSTALL EXHAUST MANIFOLD HEAT SHIELD.; (a) Install the exhaust manifold heat shield onto the

59 18. INSTALL LAMBDA SENSOR NO. 1 (a) Install the lambda sensor into the exhaust manifold. R : Lambda sensor. Torque: 44 Nm 19. INSTALL EXHAUST MANIFOLD HEAT SHIELD. (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.)...

Page 60 - (b) Install the lambda sensor harness with the clip into the; SPARK PLUG EXCHANGE; Torque 9 Nm

60 (b) Install the lambda sensor harness with the clip into the bracket. K : Clip (19-1) 21. SPARK PLUG EXCHANGE (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) Torqu...

Page 61 - Install interior compartment; (a) Install the control-unit assembly onto the studs using 3; REMOVE AUTOMATIC TRANSMISSION; disconnect the connectors)

61 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 2. REMOVE AUTOMATIC TRANSMISSION CONTROL-UNIT (AUTOMATIC TRANSMISSION ONLY). (a) Remove the 3 nuts...