URD Mk3 Supercharger System Toyota Tacoma 2.7L I4 2TR-FE. Installation Guide

Transcription

1 URD Mk3 Supercharger System Toyota Tacoma 2.7L I4 2TR-FE Installation Guide Legal in California only for racing vehicles, which may never be used upon a highway.

2 THIS URD INTERCOOLED SUPERCHARGER SYSTEM (the SYSTEM ) IS A VERY HIGH PERFORMANCE AUTOMOTIVE COMPONENT. NO PERSON WHO IS NOT AN EXPERIENCED OPERATOR OF VERY HIGH PERFORMANCE VEHICLES SHOULD DRIVE ANY VEHICLE IN WHICH THE SYSTEM IS INSTALLED. READ ALL OF THE ENCLOSED WRITTEN INFORMATION BEFORE UNPACKING, TESTING, INSTALLING OR USING ANY COMPONENT OF THIS SYSTEM. THIS MATERIAL CONTAINS IMPORTANT INFORMATION ABOUT THE SYSTEM, INCLUDING CRITICAL WARNINGS, YOUR RESPONSIBILITIES, URD s LIMITED WARRANTY AND LIMITED OBLIGATION FOR DAMAGES, CONDITIONS RELATING TO YOUR RETURN RIGHTS, AND INSTRUCTIONS FOR INSTALLING, USING AND MAINTAINING THE SYSTEM. BY OPENING THE PACKAGING FOR THE SYSTEM, THE PURCHASER ACKNOWLEDGES THAT HE WILL READ AND ACT IN ACCORDANCE WITH ALL INFORMATION SUPPLIED WITH THE SYSTEM AND WILL BE SOLELY RESPONSIBLE FOR THE INSTALLATION AND USE OF THE SYSTEM AND THE OPERATION OF ANY VEHICLE IN WHICH IT IS INSTALLED. Warnings: 1. YOUR FAILURE TO READ, UNDERSTAND, AND ACT IN ACCORDANCE WITH, THE INFORMATION CONTAINED IN THIS DOCUMENT MAY (A) ENDANGER YOUR LIFE AND, SAFETY AND THE LIFE AND SAFETY OF OTHERS; (B) CAUSE DAMAGE OR EXCESSIVE WEAR TO THE SYSTEM, YOUR VEHICLE AND/OR OTHER PROPERTY; (C) PREVENT YOU FROM BEING ABLE TO RETURN THE SYSTEM. 2. THE SYSTEM IS DESIGNED AND INTENDED ONLY (A) FOR RACING AND OTHER OFF-ROAD USE, (B) WHEN PROPERLY INSTALLED, WITHOUT MODIFICATION, ACCORDING TO URD S WRITTEN INSTRUCTIONS IN A WELL MAINTAINED VEHICLE THAT IS APPROPRIATELY CONFIGURED FOR USE ON THE APPLICABLE SPECIFIC TERRAIN, AND (C) IN A VEHICLE THAT IS OPERATED BY 2

3 A DRIVER EXPERIENCED IN THE USE OF VERY HIGH PERFORMANCE VEHICLES AND AUTOMOTIVE PRODUCTS. UNLESS ALL OF THESE CONDITIONS ARE SATISFIED, YOU SHOULD NOT USE A VEHICLE EQUIPPED WITH THE SYSTEM. 3. BECAUSE OF THE SYSTEM S VERY HIGH PERFORMANCE CHARACTERISTICS AND OPERATIONAL POTENTIAL, SAFE DRIVING OF A VEHICLE IN WHICH THE SYSTEM IS INSTALLED DEMANDS THAT CAUTION BE USED AT ALL TIMES TO ASSURE EFFECTIVE VEHICLE CONTROL. 4. THE SYSTEM HAS NOT BEEN REVIEWED OR APPROVED BY THE CALIFORNIA AIR RESOURCE BOARD, THE U.S. DEPARTMENT OF TRANSPORTATION OR ANY OTHER GOVERNMENTAL AUTHORITY. URD MAKES NO CLAIM THAT THE SYSTEM CAN BE LAWFULLY USED IN ANY VEHICLE ON A PUBLIC ROAD OR HIGHWAY OR IN ANY POLLUTION CONTROLLED VEHICLE. FEDERAL AND MANY STATE LAWS PROHIBIT THE REMOVAL, MODIFICATION OR RENDERING INOPERABLE OF ANY DEVICE OR ELEMENT OF DESIGN AFFECTING VEHICLE EMISSION OR SAFETY IN A VEHICLE USED ON PUBLIC HIGHWAYS. VIOLATION OF SUCH LAWS MAY SUBJECT THE OWNER OR USER TO A FINE OR PENALTY. 5. IN ORDER TO ACHIEVE SUPERIOR PERFORMANCE OF THE VEHICLE IN WHICH THE SYSTEM IS INSTALLED AND TO PROVIDE AN INCREASED MARGIN OF SAFETY, URD RECOMMENDS THE USE OF HIGH PERFORMANCE TIRES AND THE ADDITIONAL INSTALLATION OF A PROPERLY UPGRADED (A) VALVE BODY FOR AUTOMATIC TRANSMISSIONS, (B) SUSPENSION SYSTEM AND (3) BRAKING SYSTEM. 6. INSTALLATION OF THE SYSTEM AND URD-RECOMMENDED VEHICLE ENHANCEMENTS MAY VOID ANY APPLICABLE MANUFACTURER S VEHICLE WARRANTY COVERAGE. 7. DO NOT ATTEMPT TO INSTALL THE SYSTEM UNLESS YOU HAVE APPLICABLE AUTOMOTIVE MECHANICAL KNOWLEDGE AND EXPERIENCE. PROFESSIONAL INSTALLATION OF THE SYSTEM IS RECOMMENDED, BUT IS NOT REQUIRED. IMPROPER INSTALLATION MAY DAMAGE THE SYSTEM AND/OR THE ENGINE AND REDUCE PERFORMANCE. 8. FAILURE TO ADHERE CAREFULLY TO THE INSTALLATION AND OPERATING INSTRUCTIONS RELATING TO THE SYSTEM MAY RESULT IN INCREASED FIRE HAZARDS AND SAFETY RISKS. THE SYSTEM PRODUCES SUBSTANTIAL COMPRESSION PRESSURES, 3

4 GENERATES HIGH TEMPERATURES, CAUSES HIGH INTAKE VACUUM THAT CAN INGEST MATERIAL, HAIR AND FINGERS, AND HAS OPEN PULLEYS AND DRIVE BELTS. KEEP CLEAR OF ALL MOVING PARTS AND WEAR SAFETY GOGGLES AT ALL TIMES IN THE VICINITY OF THE SYSTEM WHEN IT IS OPERATING. 9. TIRES AND OTHER ACCESSORIES ON VEHICLES EQUIPPED WITH THE SYSTEM MAY EXPERIENCE EXCESSIVE AND PREMATURE WEAR. 10. USE OF THE SYSTEM WITH ANY GASOLINE THAT IS LESS THAN 91 (US Rating system) OCTANE AT THE RETAIL PUMP MAY REDUCE ENGINE PERFORMANCE AND DAMAGE THE SYSTEM. FOR OPTIMUM PERFORMANCE, USE 93 OR HIGHER OCTANE WHENEVER IT IS AVAILABLE. Introduction Congratulations for selecting URD s 2TR-FE Mark III (Mk3) Supercharger System. URD developed this exceptional supercharger system to enhance your Tacoma enjoyment. The system is designed around a centrifugal supercharger made by Rotrex of Denmark. The supercharger uses an innovative traction drive system that increases the impeller speed seven times faster than the spinning supercharger pulley. This traction drive allows for a highly efficient, quiet, and compact supercharger design. The URD 2TR-FE Mk3 supercharger system is a complete supercharger kit. The kit includes a pre-programmed engine management system, fuel pump, spark plugs, additional injector system, and every part needed for a complete installation and proper operation. The kit and the engine management were developed for United States specification Tacoma trucks with the 2TR-FE. It is essential that you always use the highest-octane pump gasoline available in your area. 93+ octane is preferred, but is not available in all areas. In areas where 93 octane is not available, 91 may be substituted. The engine should be restricted to RPM limits of less than 5300 RPM when 91 octane fuel is used. The engine should NEVER be run with less than 91 octane fuel with the supercharger system installed. Run two full tanks of high-octane fuel in the truck before installing the supercharger system. It is recommended that you read through the entire installation guide before the supercharger system is installed. If you have any questions or need any clarification of any of the steps, please contact URD Technical Support prior to 4

5 installation. Professional installation is recommended but not required. A basic understanding of automotive terminology and automotive systems is needed. The Mk3 drive belt is only available from URD. It is recommended that a spare belt be kept in truck along with this installation guide in the event the belt requires unexpected replacement. The oil used in the supercharger is unique traction oil and is not readily available. To be safe and sensible, check and top off the Rotrex oil system from time to time. We recommend that you have this oil on hand so it will be available if needed. Damage to the supercharger from insufficient oil supply will void the warranty. URD recommends installing kit items in order and as illustrated. If you wish to install the kit over a period of time, you can install some of the kit before the major components. If you need to install the supercharger system in stages due to time constraints, install the fuel pump kit, and the engine management system first. The remainder of the kit items must be installed together. The hardware needed to install the supercharger system is broken down into small packages specific to installation steps. Prepackaging reduces install time. URD is currently marketing this supercharger kit as an off road use only kit. This kit has not been submitted for certification by the California Air Resource Board. URD makes no claim that this kit is legal for use on any pollution controlled vehicle on any public roadway. Let the fun begin, BOOST ON!!! * BE SENSIBLE * DRIVE SAFELY * OBEY THE LAW * * ENJOY THE POWER * Tools Needed Basic mechanic tools are needed to install this supercharger system. There are a few specialty tools that are needed for the installation. 5mm Allen wrench 9/64 Allen wrench 5

6 Air driven body saw or sheet metal nibbler to cut sheet metal New engine coolant to replace what is spilled when the thermostat is changed. MORE TO BE LISTED Fuel Pump Installation and Spark Plugs 1. Install the URD High Flow Fuel Pump/Filter Kit. The upgraded fuel pump is critical to ensure sufficient fuel flow to the engine during boost. The instructions for the fuel pump and the fuel filter upgrade are located in the fuel pump upgrade kit. Please refer to those instructions. 2. Install the supplied IKH-24 Iridium Spark plugs without altering the gap on the plugs. Torque to 20 Nm (15 lb-ft). Installing the Intercooler Before beginning the installation, review the packing list and verify you have all the parts listed. It will be better to find you are missing an important part before installation starts. If you find that you are short any of the parts please contact URD at For installation or Technical Support needs, please contact URD Tech Support or 877-8URDUSA x3. 1. Disconnect the negative battery terminal. 2. Remove the Grill. A. Open the hood. Remove two screws that attach the grill to the radiator core support near the hood latch. 6

7 B. Remove two plastic rivets. Use a flat bladed screwdriver to pop up on the center of the rivet and pull the center up. This disengages the lock and you can now remove the whole rivet. 7

8 C. Pull straight upward on the grill to unsnap the lower retainers and set the grill aside. 8

9 D. If the retaining clips stay attached to the vehicle, remove them and reinsert them into the grill. If this is not done you will not be able to reinstall the grill. The clips should stay attached to the grill. 3. Cut Hole for Charge Air Piping. This can be easily done with an air driven body saw. One can be purchased from Harbor Freight for about $25. You may want to consider having a body shop cut this hole for you. The hole will need to be cut BEFORE you start disassembling components so the vehicle is still drivable. A. Place the template on the radiator support and trace the line to be cut with a Sharpe marker or grease pencil. 9

10 B. Make sure there is nothing on the backside of the radiator support that you may not want to cut through. C. Cut out the opening. Smooth the cut edge with a file or sandpaper. It is recommended to paint the cut edge to prevent rusting. 10

11 D. Place the included plastic combing material on the cut edge to prevent damage to components passing through the hole. E. After completing the passenger side flip the template over so it is a mirror image and do the very same for the driver s side. Intercooler System 1. Install the intercooler. 11

12 A. Using a 10mm socket remove the bolt that secures the A/C condenser to the radiator support on the passenger side. Install the passenger side intercooler mounting bracket using a M6x1.0x35mm socket headed cap screw and a 6mm washer in the single round hole on the bracket. Leave it loose for now. B. Remove the hood latch cover plate and hood latch. C. Remove the hood latch support bracket. There is a bolt on the top, one on the lower cross member, and two nuts on the bumper. One nut is hidden under the bumper cover. You can gain access to it by removing the plastic rivets and puling the bumper cover back a bit to expose that hidden nut. D. Remove the two horns. E. Set the intercooler into position and secure it by using an M8x1.25x20mm socket headed cap screw in the passenger side bracket. Leave it loose for now. 12

13 F. Attach the driver s side mounting bracket and leave it loose for now. G. From under the vehicle secure the lower intercooler mounting tab to the lower cross member with a M6x1.0x20mm socket headed cap screw and washer. Leave it loose for now. 13

14 H. Bend the lower tab on the hood latch forward to a 90 degree angle. Attach that tab to the intercooler threaded mount using an M8x1.25x10mm socket headed cap screw and 8mm washer. Adjust the positioning of the intercooler so that you can reinstall the hood latch to the radiator support using the original hardware. I. Install the horns on each of the side intercooler mounts. Slightly bend the horn mounts to get them to lay as flat as possible on the top of the intercooler. Extend the wire to the passenger side horn using the included butt connectors and wire extension. J. Pay special attention to the A/C condenser pipe on the driver s side. Make sure there is sufficient clearance between the intercooler and the A/C pipe. You may need to shim the driver s side mount forward with some washers. K. Once you are satisfied with the intercooler position, tighten all the mounting bolts. 2. Install Supercharger Intake Piping A. Remove the main air induction tube that runs from the air filter box to the throttle body. There is a pressure sensor that is bolted to it, so 14

15 detach it from the main air induction tube leaving the vacuum line attached. Secure it to main wire harness with a wire tie. B. On the driver s side, install a degree silicone elbow with a 3 liner clamp on the intercooler side and a 2.5 liner clamp on the pipe side. C. Install a 2.75 straight coupler on the throttle body. D. Remove the MAF Sensor from the air filter box and install it in the MAF mount on Charge Pipe #2 and secure it with the provided M4 SHCS. E. Install the MAF Delete plate in the air filter box using the stock screws. Use a small amount of silicone RTV to seal the plate to the air filter box. 15

16 F. Install Charge Pipe #2 with the smaller end at the intercooler. Leave it loose for now. 16

17 G. Relocate the MAF Sensor harness so it will reach to the new location of the MAF sensor. This is done by removing the MAF harness from the factory loom wrap all the way to the first junction where it meets the larger wire harness. Install the provided loom wrap on the exposed MAF harness and guide it over to the MAF sensor. Secure the MAF harness to the larger harness that wraps around the front of the engine with the provided wire tie wraps. H. Connect a new section of vacuum line from the fuel pressure regulator to the nipple on Charge Pipe #2. This will cause the fuel pressure to be increased under boost. Tip- Carry a couple hose clamps in the different sizes in the vehicle and a screw driver or nut driver. This is so you can reinstall a charge pipe or intake pipe that comes loose while driving. 17

18 Supercharger Mounting 1. Remove Accessory Drive Belt. Pay close attention to the unusual routing of the accessory drive belt. The supplied belt will follow the same routing with the exception that it is routed from the power steering pump pulley to the supercharger pulley. A. Remove the stock belt by using a 14mm socket and a long handle ratchet. Reach down from the top and place the socket on the tensioner. There is a Hex cast into the tensioner arm for you to place the socket on. Release the tension from the tensioner and remove the drive belt. B. Remove the belt from the engine and feed it around fan. Remove it completely from the vehicle. 3. Supercharger Bracket A. Remove the wire harness support bracket bolt from the front of the timing chain cover. Tuck the bracket out of the way. This is needed to give the needed clearance to the supercharger mounting bracket. B. Remove the bolt from the very top passenger side of the timing chain cover. This will be replaced with a new bolt later. 18

19 C. Remove the two mounting bolts for the alternator. Keep the bottom one as it will be reused later to mount the supercharger bracket. D. Install one idler pulley to the driver s side of the supercharger mounting bracket. You will need to place a spacing washer between the pulley and the bracket. Secure with a stainless M8x1.25x40mm SHCS. This pulley should be installed now to eliminate a clearance issue with the cooling fan shroud. The front side of the bracket is completely flat and the rear side has material removed from it. 19

20 E. Place the supercharger mounting bracket on the engine and start the lower mounting bolt reusing the one that was removed earlier. F. Place the flat head cap through the middle mounting hole on the supercharger bracket and place the short spacer between the bracket and the upper alternator mounting hole. Just start the threads and leave it loose. G. Make sure the MAF wire harness and main wire harness are guided between the recess in the mounting bracket and the cam cover so they will not be pinched by the bracket installation. H. Start the long mounting bolt in the upper bracket mounting hole with the long spacer between the bracket and engine. Just start the threads. I. Carefully snug up the flat headed cap screw first then snug the other two mounting bolts. Once you are satisfied with positioning of the bracket tighten all the bolts to permanently secure the bracket to the engine. Do not over tighten the flat headed cap screw. They tend to take way more torque to remove than to install. J. Install the second idler pulley placing spacing washer and an M8x1.25x40mm SHCS. 2. Mount the supercharger to the Bracket. 20

21 NEED SUPERCHARGER CLOCK EXAMPLE IMAGE A. Check the clock position of the output port on the supercharger. If not as in the picture you will need to adjust it prior to installation. B. If you need to adjust it place the supercharger on the work bench with the pulley facing up. Remove the two LARGER recessed cap screws and rotate the compressor house around to the needed position and reinstall the recessed bolts to lock it into position. Do not remove the smaller recessed bolt as this will void the warranty on the supercharger. C. Place the supercharger on the mounting bracket and install the four mounting bolts to secure it to the bracket. Oil System The supercharger has its own self-contained oiling system that uses special high tech traction oil. The system consists of an internal pump built into the supercharger, an oil reservoir mounted in the engine bay, oil cooler, hoses, and an oil filter. 21

22 You must only use Rotrex Traction Oil for your supercharger. Other oils may permanently damage the supercharger and void the warranty. If for some reason you have to modify the installation of the oil cooler to fit some custom modification to your truck, make sure that it is mounted in the proper orientation. The hose fittings must face upward so the cooler will properly fill and not trap air in it. If you have to mount it so the hose fittings are facing the side the hoses should be oriented so the oil flows in the bottom fitting and out of the top fitting. It also should be mounted in such a way to provide the needed airflow for proper supercharger cooling. The oil system uses banjo fittings on the supercharger and oil tank. This consists of a hollow bolt, a banjo fitting, and two copper sealing washers. To assemble the fitting, place one copper washer on the hollow bolt, and then the banjo fitting, then another copper sealing washer. Now you can screw it into the tank or supercharger. It is very important that the oil lines do not get pinched. When the oil lines are bent they must have a minimum of a 6 bend radius or the flow of oil will become restricted and the supercharger will not receive the proper oil flow. 22

23 The flow of oil goes from the bottom port on the supply tank through a special filter to the IN port on the supercharger. It then flows from the OUT port of the supercharger to the oil cooler. It then flows from the oil cooler back to the top port on the oil tank to complete the circuit. 1. Install the oil cooler. 23

24 A. The oil cooler mounting bracket is fitted with special pressed in nutserts. Those must be on the rear side of the brackets. Attach the cooler to the mounting bracket using two M6x1.0x20mm socket headed cap screws and 6mm washers. The cooler is installed so the hose fittings are facing upward. B. Install the 3/8 oil lines to each of the hose fittings on the cooler and secure with the 3/8 clamps. C. Attach the oil cooler mounting bracket to the cross member on the passenger side. The backing plate should be inserted into the cross member with the nut-serts facing the engine. Thread two M8x1.25x20mm socket headed cap screws and 8mm washers through the oil cooler mounting bracket, through the existing holes in the cross member and into the backing plate inside of the cross member. 24

25 In this picture, wire loom has been used to cover the oil lines to prevent chafing and to protect the oil lines (optional). The picture is of the V6 installation. For the 2TR-FE the oil line from the driver s side port will run through the driver s side head light opening to the oil tank. D. Run one oil line from the passenger side of the supercharger, labeled OUT, to the passenger side nipple on the oil cooler. You can route it out through the opening for the headlight. E. Attach the other oil line to the driver s side of the oil cooler and route it over to the driver s side headlight opening and between the battery and inner fender wall. This will be attached to the top port on the oil tank to be installed in the next step. 2. Install the Supercharger Oil Supply Tank. 25

26 A. Install the banjo fittings to the upper and lower port on the oil tank. Adjust them so that the lower one will point to the engine and the upper one will face and point to the front of the vehicle. Once you have them oriented properly tighten them. B. Place the oil tank mounting clamps on the oil tank. Next attach the mounting clamps to the oil tank bracket. Note that it will attach to the two holes on the drivers inner fender wall and has a bend in it so that when attached the tank will be straight up and down. There is a tapered edge in the bracket to clear a wire harness. Once you have it oriented correctly tighten the bolts that attach the tank brackets to the main bracket. Leave the tank brackets loose for now. C. Install the 6 section of oil line to the lower banjo bolt and secure it with a spring clamp. 26

27 D. Mount the main bracket to the inner fender wall using the two hex head M8x1.25x20mm bolts. E. Adjust the height of the oil tank in the mounting brackets so the oil tank is as high as possible while having sufficient hood clearance then tighten the mounting bracket bolts. F. Attach the oil line from the oil cooler to the top oil tank banjo bolt and secure it with a spring clamp. 27

28 G. Install the Rotrex oil filter to the 6 oil line attached to the bottom of the oil tank. Make sure the flow direction arrow is pointing toward the supercharger. 28

29 H. Attach the 30 section of 5/16 oil hose to the filter and route it over the engine to the IN port on the supercharger and secure it to the banjo fitting on the supercharger with a spring clamp. I. Fill the oil tank to the MAX mark on the oil tank dip stick with the Rotrex Supercharger Traction Oil. You will top it off later once the engine is running. DO NOT OVER FILL THE OIL TANK. 3. Install the drive belt Need belt routing graphic here A. The belt follows an unusual routing path. Pay particular attention to the belt routing. B. Slip the belt over the fan. Start the installation by placing it around the crank pulley and then working outward toward the A/C compressor. Follow a counter clockwise pattern. C. The belt is a 7 rib belt and the supercharger is an 8 rib pulley. The belt should be installed in the forward 7 grooves on the pulley leaving the last groove on the pulley empty. 29

30 D. Leave the belt off of the driver s side idler pulley. Double check the belt routing several times and make certain it is in all the grooves on each pulley. E. Using a 14mm socket and a long handle extension relieve the tension of the tension pulley and slip the belt over the idler pulley. Slowly let the tensioner take up tension on the belt. F. Inspect the belt installation and make certain that the routing is correct and the belt is sitting properly on each pulley. 4. Install intake elbow and charge pipe 30

31 A. Install the supercharger intake elbow to the air filter box and supercharger inlet and secure it with a 3 liner clamp at each end. B. Install the crank case breather tube to the port on the rear of the cam cover and to the smaller port on the supercharger intake elbow. Use the three smaller clamps to secure it. C. Install the degree elbow on the supercharger discharge port. Install a degree elbow onto the passenger side of the intercooler and secure it with a 3 and 2.5 liner clamps. Leave it loose until final adjustment is made. D. Install Charge Pipe 1 to the supercharger discharge port and the supercharger inlet. You may need to trim the silicone coupler on the discharge port for proper fitment. 31

32 E. Install the Bosch bypass valve into the port on the supercharger intake elbow. The vacuum hose nipple should be facing upward. F. Install the 1 bypass hose with the 90 degree bend at the bypass valve and the other end at the fitting on the Charge Pipe. You will need to trim it for proper fitment. G. Attach the vacuum line to the bypass valve. H. Secure the bypass valve with the 1 clamps and make final adjustment of the charge pipe and tighten the clamps. Install the engine management system. 1. Install the engine management system A. The unit installed under the passenger side of the dash and can be secured to the large wire harness that runs under the main ventilation fan unit with the supplied wire ties. B. Connect it to the ECU wire harness using the provided connection guide. The ECU is located behind the glove box. 32

33 C. Remove the glove box by opening it and then removing the damper on the passenger side. D. Then squeeze the sides of the glove box together to disengage the travel stops and open it just past the point where it is level with the floor. Now you can pull it straight back and this will unsnap the hinge. E. You can now complete your harness connections. F. On the firewall there is a small rubber grommet on the passenger side. Remove it and using a coat hanger feed the fuel injector harness through from the engine side and into the dash area. Attach the fuel injector harness to the EMS using the wiring guide. G. Route the harness following the main engine harness and over the additional injector on the charge pipe and plug it in. H. Feed the hard vacuum line through the same hole in the fire wall and route it to the internal MAP sensor on the EMS and attach it. Double check the routing to make sure it is not kinked anywhere. I. Route the hard line to the area of the throttle body. Remove the large vacuum line that is attached to the intake manifold just under the throttle body. You will cut it in two locations like in the picture and insert the two provided vacuum T fittings. The one with the short 33

34 vacuum should be installed closest to the manifold and that is what you will attach the hard vacuum line to. J. Install the short section of vacuum line to the other T fitting and run toward the blow off valve. Insert the small T into that line and run a short section of vacuum line to the blow off valve and the other over to the bypass valve located in the supercharger intake elbow and attach it. Install fuel line 1. Install the supplemental fuel system. A. Remove the fuel rail pulse damper from the rear part of the fuel injector rail. 34

35 This picture shows the new coolant hose installed. It is the shinny one without the protective covering. This needs to be replaced so it will clear and run over the raised fuel rail pulse damper. B. There is a coolant hose that carries engine coolant to the throttle body that will need to be relocated. Remove it. A new line will be installed later. C. Install the URD fuel rail tap between the fuel rail pulse damper and the fuel rail with the fuel port facing toward the front of the vehicle. Lubricate the O ring on the URD fuel rail tap with motor oil before installing. D. Once in position lubricate the O-ring on the pulse damper and insert it into the URD fuel rail tap and secure it with the provided bolts. E. Attach end of the fuel line to the fuel tap that has the 90 degree bend in it and route it out toward the driver s side fender and around to the fuel injector mount and attach it. F. The fuel line uses AN fittings and the proper way to install them it to screw them on finger tight and then with a wrench turn them ¼ turn more. You will need to put a smaller wrench on the fitting that the fuel 35

36 line attaches to so that it will not turn while you are tightening the fitting. Final 1. Go ever the entire installation and verify that everything is properly installed. A. Recheck the oil system hose routing and oil level. B. Reconnect the negative battery terminal. C. Recheck and make sure the vacuum line is properly connected to the bypass valve. D. Recheck the drive belt routing. E. Recheck all the intake and charge air plumbing. F. Recheck the power steering hose. Make sure it is tied back away from the supercharger belt. 2. Engine start. A. After verifying everything is properly installed, make sure you have a fire extinguisher handy and start the engine for just three seconds and shut it off. B. Inspect the drive belt to make sure it is tracking properly and it is not coming in contact with anything it should not. C. Look and smell for fuel leakage from the new injectors. D. Restart the engine and let it idle for at least 10 minutes. E. Check the supercharger oil level in the oil tank with the engine is running and adjust the level as needed according to the dipstick. The oil level in the tank should drop right after the engine is started while the oil fills the hoses, supercharger and supercharger oil cooler. That will ensure you have routed the oil system properly. If this is not the case, shut the engine off and correct the problem. If the supercharger is operated without the oil system installed correctly the supercharger will be seriously damaged and void the warranty on the supercharger. 36

37 F. Take the truck for a very short test drive keeping the engine speed low and use minimal power settings. Inspect the entire installation paying special attention to the drive belt and oil system. G. Once you are certain the entire kit has been properly installed and working correctly, take the truck for a test drive lasting about 10 minutes. H. Inspect the entire system looking for anything that is rubbing or chafing and look for oil and fuel leaks. I. The truck should now be ready for an extended test drive. Please resist using full power right away. You will need the engine control system to adjust to the demands of the supercharger system. Slowly ease into higher RPMs and power settings over time. J. Perform ongoing regular inspections checking fluid levels and to make sure all the hoses, wiring, belt for signs of unusual wear. Operating Limitations The kit and engine management was developed for the USDM Tacoma trucks with the 2TR-FE engine. It is essential that you always use the highest-octane gasoline available in your area. 93 octane or higher is preferred, but is not available in all areas. In areas that 93 octane is not available 91 may be substituted provided that it does not lead to audible boost induced spark knock. If boost induced spark knock is ever heard you should instantly reduce power until the knock goes away. If it continues, discontinue operation and contact URD Tech Support. The engine should never be run with less then 91 octane fuel with the supercharger system installed. You should run at least two full tanks of high-octane fuel in the truck before the installation of the supercharger system. It is possible to exceed the capacity of the engine s cooling system. The engine cooling system was designed to support the stock engine and the supercharger system will put a greater thermal load on the engine s cooling system. In the testing we have done at URD we were not able to exceed the stock engine cooling system s capacity when operated on public roads, or at any other time. While we believe you should not have an issue in normal operation, you as the vehicle operator need to be aware of the potential to do so. If you push the engine very hard with extended periods of boost you should carefully monitor the engine temperature gauge and reduce power if you notice a higher 37

38 then normal temperature. The cooling system should also be flushed and refilled with fresh coolant every 30,000 miles. You can improve airflow over the supercharger intercooler by installing the GrillCraft MX series grill. The health of the fuel system is important for proper supercharger operation. The supercharger system will put greater demands on the fuel system than the stock engine. You must take steps to maintain the fuel system to ensure proper operation. URD recommends that you use a high quality fuel injector cleaner every oil change. URD recommends BG 44K fuel injector cleaner. At least every 30,000 miles you should have a professional fuel system service performed. This type of service connects your fuel line to a special machine and runs your engine on a special solution for a period of time. This cleans the injectors, the intake valves and the combustion chamber of all built up carbon. This will keep the compression ratio at like new specifications. During testing URD saw a reduction in fuel pressure at full boost when the fuel tank level dropped below ¼ tank. The fuel pump pulls fuel from a small bucket inside of the fuel tank. When the fuel level drops below a ¼ tank, it is possible to pull the fuel from that bucket faster than it can refill and the fuel pump can run out of fuel for the engine. You should never boost the engine when the fuel tank level is below ¼ tank. Overall fuel delivery is very important to maintain a safe air/fuel ratio for proper supercharger operation. For that reason URD recommends that you install a wideband type air/fuel ratio display unit. This will give you an instant indication if something happened to the fuel delivery system and allow you to reduce power preventing engine damage. URD has several different types available, so you can pick the one that fits your needs. The advanced engine management URD includes in the supercharger kit has an engine guardian feature. It will limit the maximum engine RPM until the engine warms up and then again if it begins to overheat. The guardian will also engage if the fuel mixture it not as expected. If you are at 85% throttle or higher and the fuel mixture is to rich, or to lean for more than one second the guardian will engage and drastically lower the engine rev limit. If you notice the engine rev limiter kicking in unexpectedly and see the check engine light come on solid, it is likely the engine guardian engaging to save the engine. Immediately close the throttle and determine what the problem is. 38

39 Maintenance Regular inspections of the entire system should be made on a regular basis. You should check for: Leaks Loose fasteners Loose brackets Unusual belt wear Chafing of the hoses Chafing of the wire harnesses Fluid levels. It is normal for a slight amount of oil to be consumed. The proper level must be maintained to prevent damage to the supercharger. Every 30,000 miles or once a year the supercharger oil and oil system s oil filter must be changed. Replacement filters and traction oil are available from URD. Warranty 1. URD S LIMITED WARRANTY AND LIMITED OBLIGATION FOR DAMAGES A. URD WARRANTS ONLY THAT THE SYSTEM, OTHER THAN THE ROTREX SUPERCHARGER, WILL BE FREE FROM MANUFACTURING DEFECTS IN MATERIAL AND WORKMANSHIP FOR NINETY (90) DAYS AFTER THE INITIAL PURCHASE OF THE SYSTEM, EXCEPT THAT THE WARRANTY PERIOD FOR MAP-ECU3 EGNINE MANAGEMENT SYSTEM IS ONE (1) YEAR AFTER THE INITIAL PURCHASE OF THE SYSTEM THIS WARRANTY IS PROVIDED BY PERFORMANCE MOTOR RESEARCH. URD WILL NOT ACCEPT A WARRANTY CLAIM UNLESS URD RECEIVES WRITTEN NOTICE OF SUCH CLAIM WITHIN THE APPLICABLE WARRANTY PERIOD STATED ABOVE. B. THE WARRANTY FOR THE ROTREX SUPERCHARGER IS MADE SOLELY BY THE MANUFACTURER AND NOT BY URD. SEE FOR THE TERMS AND CONDITIONS OF THE WARRANTY APPLICABLE TO THE ROTREX SUPERCHARGER. 39

40 C. THIS WARRANTY (1) IS ONLY FOR THE BENEFIT OF THE INITIAL PURCHASER OF THE SYSTEM, (2) IS NON- TRANSFERABLE, AND (3) SHALL BECOME VOID IMMEDIATELY IF TRANSFERRED OR IF WARRANTY RIGHTS ARE CLAIMED BY ANYONE OTHER THAN THE INITIAL PURCHASER. D. NOTWITHSTANDING ANYTHING TO THE CONTRARY, THIS WARRANTY SHALL BE VOID AND OF NO FURTHER FORCE OR EFFECT IF ANY PORTION OF THE SYSTEM IS DAMAGED OR ALTERED BECAUSE OF (1) IMPROPER INSTALLATION, (2) TAMPERING OR MODIFICATION, INCLUDING (WITHOUT LIMITATION) ATTACHING A SMALLER OR HIGHER BOOST PULLEY TO THE SYSTEM, (3) INADEQUATE OR IMPROPER MAINTENANCE, OR (4) ANY ACT OR OMISSION BEYOND URD S DIRECT CONTROL, INCLUDING (WITHOUT LIMITATION) AN ACCIDENT INVOLVING THE VEHICLE IN WHICH THE SYSTEM IS INSTALLED. E. URD SHALL HAVE NO RESPONSIBILITY OR LIABILITY FOR ANY (1) DAMAGE TO OR LOSS OF USE OF ANY VEHICLE OR OTHER PERSONAL PROPERTY (EXCEPT THE SYSTEM IN ACCORDANCE WITH THIS WARRANTY), (2) PERSONAL INJURY TO OR DEATH OF ANY PERSON, (3) ADVICE NOT GIVEN BY URD IN WRITING, OR (4) ANY FAILURE OF THE PURCHASER TO COMPLY WITH THE INSTRUCTIONS OR TO RESPOND APPROPRIATELY TO THE WARNINGS IN THE MATERIAL ACCOMPANYING THE SYSTEM. F. URD MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THE SYSTEM OR ANY PART THEREOF. URD MAKES NO OTHER EXPLICIT OR IMPLIED WARRANTY WITH RESPECT TO PERFORMANCE, FUNCTIONALITY, MECHANICAL, ELECTRICAL OR ELECTRONIC COMPATIBILITY, OR OTHERWISE, EXCEPT AS LIMITED, CONDITIONED AND SET FORTH IN THIS GUIDE. G. URD S LIABILITY FOR BREACH OF WARRANTY SHALL BE LIMITED, IN URD S DISCRETION, TO REFUNDING THE PURCHASE PRICE FOR OR REPLACING THE SYSTEM OR APPLICABLE PART THEREOF THAT URD DETERMINES IS ELIGIBLE FOR A WARRANTY CLAIM. 40

41 URD SHALL, IN NO EVENT, HAVE ANY LIABILITY FOR ANY INDIRECT OR CONSEQUENTIAL DAMAGES OR LOSS OF INCOME OR PROFITS. H. SEE THE FOLLOWING SECTION FOR FURTHER INFORMATION RELATING TO WARRANTY CLAIMS. 2. CONDITIONAL RIGHT TO RETURN THE SYSTEM A. ALL SALES ARE FINAL AND NO SYSTEM OR COMPONENT IS ELIGIBLE FOR RETURN FOR REFUND OR CREDIT OR FOR WARRANTY REPLACEMENT, EXCEPT AS DETERMINED BY URD IN ITS SOLE DISCRETION AND UPON THE REQUEST OF A PURCHASER OF THE PRODUCT. URD S DECISIONS ARE FINAL ON ALL MATTERS RELATING TO RETURNS AND WARRANTY REPLACEMENT. B. IF THE PURCHASER REQUESTS AND URD ISSUES A RETURN MERCHANDISE AUTHORIZATION ( RMA ) NUMBER, THE PURCHASER SHALL SHIP THE RMA- IDENTIFIED ITEMS (EACH CLEARLY MARKED WITH THE RMA NUMBER) TO URD (FREIGHT PREPAID) AT 3111 QUAIL RIDGE WAY, HUNTINGTOWN MD AND SHALL REQUEST EITHER (1) RETURN FOR REFUND OR CREDIT OR (2) WARRANTY REPLACEMENT. C. URD WILL NOT ACCEPT ANY ITEM FOR RETURN FOR REFUND OR CREDIT, UNLESS SUCH ITEM (1) IS IN NEW AND UNUSED CONDITION, (2) HAS NEVER BEEN INSTALLED, ALTERED OR MODIFIED, AND (3) IS RECEIVED BY URD WITHIN 30 DAYS AFTER PURCHASE WITH THE ORIGINAL SALES INVOICE AND PACKAGING MATERIAL. ANY RETURNS NOT MEETING ALL OF THESE CRITERIA WILL BE RESHIPPED TO THE PURCHASER VIA FREIGHT CHARGES COLLECT. ANY RETURNED ITEM ACCEPTED BY URD FOR REFUND OR CREDIT SHALL BE SUBJECT TO A RESTOCKING FEE EQUAL TO 20% OF THE INVOICE PRICE OF THE RETURNED ITEM. D. IF A PURCHASER SHIPS AN ITEM TO URD AND REQUESTS A WARRANTY REPLACEMENT OF THAT ITEM, URD SHALL EXAMINE THE ITEM AND DETERMINE IN ITS DISCRETION WHETHER SUCH ITEM IS ELIGIBLE 41

42 FOR WARRANTY REPLACEMENT. IF URD DETERMINES THAT THE ITEM IS ELIGIBLE FOR WARRANTY REPLACEMENT, URD SHALL DELIVER A REPLACEMENT ITEM TO THE PURCHASER AT NO ADDITIONAL CHARGE. IF URD DETERMINES THAT THE ITEM IS NOT ELIGIBLE FOR WARRANTY REPLACEMENT, URD SHALL RESHIP THE SUBJECT ITEM TO THE PURCHASER VIA FREIGHT CHARGES COLLECT. 42