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Toyota pmn Installation Instructions Manual

Lhd/rhd turbo kit
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1
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.
LHD/RHD TURBO KIT
ATTENTION
INSTALLATION

INSTRUCTION MANUAL

ISS
REVISION RECORD
0
NEW
1
Revision
TOYOTA MOTORSPORT GMBH
MR 2
1ZZ-FTE
DATE
Oct. 05
Oct. 05
REVR.
1.0
1.1

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  • Page 1: Instruction Manual

    LHD/RHD TURBO KIT 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS ...3 PRECAUTIONS ...6 PREPARATION ...7 1. SST (Special Service Tools) ...7 2. Lubricants / Liquids ...7 VEHICLE LIFT LOCATIONS ...8 PARTS ...9 1. Location ...9 1.1. Turbo charger ...9 1.2. Heat shield...10 1.3. Exhaust manifold ...11 1.4. Intercooler...12 1.5.
  • Page 4 10. Intercooler preparation ...40 1. Install lower bracket..40 2. Install upper bracket..40 11. Pre-catalyser heat shield preparation ...41 1. Install pre-catalyser heat shield..41 12. Turbo control system preparation ...42 1. Turbo control system preparation..42 2. Install control-unit harness..42 13.
  • Page 5 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)..61 4. Install ground connection..62 5. Connect wiring harness..62 18.

  • Page 6: Precautions

    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.

  • Page 7: Preparation

    PREPARATION SST (Special Service Tools) 09032-00100 Oil pan remover 09228-06501 Oil filter wrench 09816-30010 Oil pressure switch wrench 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.

  • Page 8: Vehicle Lift Locations

    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: Swing arm 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).

  • Page 9: Parts

    PARTS 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 17-3 16-4 17-2 17-3 17-7 13-2 17-1 13-3 13-1 13-3...

  • Page 10: Heat Shield

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

  • Page 11: Exhaust Manifold

    1.3. EXHAUST MANIFOLD...

  • Page 12: Intercooler

    1.4. INTERCOOLER...

  • Page 13: Air Intake

    1.5. AIR INTAKE 25-3 25-2 25-3 25-1 25-1 25-4 2-11 12-4 17-6 2-10 12-1 12-3 2-10 2-10 12-4 12-1...

  • Page 14: Oil Filter

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

  • Page 15: Oil Pan And Brackets

    1.7. OIL PAN AND BRACKETS 14-2 14-7 14-1 14-6 27-1 14-5 14-6 19-1 20-3 20-1 19-2 20-2...

  • Page 16: Electric Components

    1.8. ELECTRIC COMPONENTS 23-1 23-6 35-1 23-5 23-5 24-6 24-6 23-2 24-9 24-9 24-7 24-7 24-2 24-2 23-4 24-8 24-8 24-8 24-3 23-9 23-8...

  • Page 17: Cooling Fan

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

  • Page 18: Templates

    1.10.TEMPLATES 2-12 27-2 27-4 21-2 21-5 21-5 27-1 21-4 Cutting lines for hose 21-4 21-3 21-1 27-5 27-3...

  • Page 19: Heat Insulation, Stickers And Sparkplugs

    1.11. HEAT INSULATION, STICKERS AND SPARKPLUGS 26-1 11-2 11-2 11-2 11-2 11-1 26-2...

  • Page 20: Parts List

    Parts List 1.0 KIT, AIRBOX Bellow with spring clamps Airfilter, sport 2.0 KIT, INTAKE TURBO Hose clamp 50-70 Pipe Airbox turbo Bracket, pipe airbox-turbo Hose, intake Turbo Air connection Bolt, hexagon socket M10X30X1.5 Washer Nut, hex head M10X1.5 Spring washer 2-10 Bolt, hex head M6X1X12 2-11 Nut, hex head M6X1 2-12 Edge protection...
  • Page 21 7.0 KIT, INTERCOOLER Intercooler Bracket, intercooler, No.1 Bracket, intercooler, No.2 Bracket, intercooler, No.3 Cushion M8 Bolt, hex head M8X12X1.25 Nut, hex head M8X1.25 Bolt, hex headM10X20X1.25 8.0 KIT, COOLED AIR Pipe Intercooler to throttle plate Hose with bead Hose, throttle body Hose clamp 40-60 Hose clamp 60-80 Clamp...
  • Page 22 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 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//M14X1.5...
  • Page 23 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...

  • Page 24: Specified Torque

    Specified torque Part tightened Harness fixation clamp Oil return adapter Oil change plug Air guide bracket Cooling-fan Temperature sensor bracket Temperature sensor Vacuum hose adapter Heat shield catalyser Turbo control-unit (Turbo) relays Water oulet adapter Water inlet adapter Water inlet hose Water outlet tube Oil pressure tube Pressure actuator...
  • Page 25 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 11.5 17.9...

  • Page 26: Installation Procedures

    INSTALLATION PROCEDURES 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.

  • Page 27: Air Hose And Clamp

    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 3-5mm...

  • Page 28: Parts To Be Removed (See Workshop Manual For Detailed Instructions)

    Parts to be removed (see workshop manual for detailed instructions)
  • Page 29 ONTINUED...

  • Page 30: Vehicle Preparation

    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.

  • Page 31: Hole Preparation

    Ø 27 mm 3. HOLE PREPARATION. (a) Drill the hole out to 11.2 mm. Ø 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.

  • Page 32: Airfilter Box Heat Shield Preparation

    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.(2-12)

  • Page 33: Oil-Sump Preparation

    Oil-sump preparation Ø 4 mm Ø 6,5 mm Ø 12 mm 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.

  • Page 34: Underbody Protection Preparation

    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.
  • Page 35 Ø 4 mm Ø 11,5 mm (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.
  • Page 36 (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) (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)

  • Page 37: Engine Cover Preparation

    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

    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 2.

  • Page 39: Inlet Pipe Preparation

    Inlet pipe preparation Ø 6.5 mm 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.

  • Page 40: Intercooler Preparation

    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

    11. Pre-catalyser heat shield preparation 5 mm 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 clearance between the clamp and...

  • Page 42: Turbo Control System Preparation

    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 relays onto the bracket using 2 bolts and 2 nuts.

  • Page 43: Turbo Preparation

    13. Turbo preparation 1. TURBO PROTECTION. CAUTION: Cover all the inlet and outlet holes with 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 actuator.

  • Page 44: Install Water Outlet Hose

    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 tube onto the water inlet adapter.

  • Page 45: Install Pressure Actuator Hose

    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...

  • Page 46: Installation Engine Compartment

    14. Installation engine compartment K 5x 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) Torque: 37 Nm...

  • Page 47: Install Turbo Charger Bracket

    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: Bush (5-6)

  • Page 48: Install Water Outlet Connections

    (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 tube and the engine water connection.

  • Page 49: Installation Engine Compartment Lower

    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 and 2 nuts.

  • Page 50: Install Oil Pressure Switch

    45˚ 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.

  • Page 51: Install Oil Pressure Tube

    8. INSTALL OIL PRESSURE TUBE. (a) Install the oil pressure tube onto the inlet pipe using the clamps. K: Clamp (2 pcs.) (13-4) 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.
  • Page 52 (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 NOTICE: When applying the correct torque to the fixation bolts ensure the correct positioning of the Intercooler and clearance from surrounding parts.

  • Page 53: Installation Engine Compartment Upper

    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.

  • Page 54: Modify Engine Ventilation Hose

    (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 the engine ventilation hose with the hose clamp onto the engine connection.

  • Page 55: Install Vsv Connections

    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.

  • Page 56: Install Exhaust Pipe Pre-Catalyser

    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 57: Install Oil Return Hose

    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) 16. INSTALL WIRING HARNESS. (a) Insert the 15A fuse into the wiring harnesss fuse- socket.

  • Page 58: Install Cooling Fan Cover

    (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 Ensure that the harness is secured every 15 cm using the tie wraps.

  • Page 59: Install Lambda Sensor No. 1

    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.

  • Page 60: Spark Plug Exchange

    (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.

  • Page 61: Install Interior Compartment

    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. (b) Remove the control-unit and put it aside.

  • Page 62: Install Ground Connection

    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.

  • Page 63: Parts To Be Installed (See Workshop Manual For Detailed Instructions)

    18. Parts to be installed (see workshop manual for detailed instructions) 20-4...
  • Page 64 ONTINUED...

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