3.4L V6 SUPERCHARGER 7 TH INJECTOR KIT

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1 Part Number: Section I Installation Preparation Kit Contents Item # Quantity Reqd. Description th Injector Block 2 1 Injector Block Gasket 3 1 1/8 NPT Brass Plug 4 2 Stud, 1-5/8 5 5 Banjo Bolt Crush Washer 6 1 Double Banjo Bolt 7 1 Fuel Injector Supply Hose 8 1 1/8 NPT Nipple, ¾ Long 9 1 Vacuum Hose, 9.5mm O.D. coupled to 6.8mm O.D Sticker, EO 11 1 Sticker, Diagnostic 12 1 Split Tubing, ¼ x Wire Tie, Large 14 1 Wire Tie, Medium 15 1 Wire Tie, Small 16 1 Hose Clamp 17 1 Intake Hose, 3-1/4 I.D M Fastener Strip (4 ) 19 1 Adhesive Foam (6 ) 20 1 TRD ECU 21 1 TRD ECU Adapter & Harness 22 1 TRD Thermostat Runner & Tacoma Runner & Tacoma 2004 Tacoma (Auto) 2004 Tacoma (Manual) 2004 D-Cab 2004 D-Cab Pre-Runner 2004 S-Runner General Applicability Runner (CA-spec. & 50-state only) and Tacoma (CA-spec. & 50-state only) with 3.4L V6 and TRD Supercharger Recommended Sequence of Application Item # Accessory 1 Fuel & Air Kit 2 ECU & Wire Harness *Mandatory Notes and Recommendations 1. Verify the standard supercharger installation before adding the 7 th injector upgrade. 2. Change the spark plugs to Denso IK20 (TRD part number , not supplied), gapped to Additional Items Required For Installation Item # Quantity Reqd. Description 1 1 roll Solder 2 1 Soldering Iron Conflicts Note: ECU not calibrated for non-ca spec. vehicles and wire harness plugs are different. Page 1 of 20

2 Item # Quantity Reqd. Description th Injector Block 2 1 Injector Block Gasket 3 1 1/8 NPT Brass Plug 4 2 Stud, 1-5/8 5 5 Banjo Bolt Crush Washer 6 1 Double Banjo Bolt 7 1 Fuel Injector Supply Hose 8 1 1/8 NPT Nipple, ¾ Long 9 1 Vacuum Hose, 9.5mm O.D. coupled to 6.8mm O.D Sticker, EO 11 1 Sticker, Diagnostic 12 1 Split Tubing, ¼ x Wire Tie, Large 14 1 Wire Tie, Medium 15 1 Wire Tie, Small 16 1 Hose Clamp 17 1 Intake Hose, 3-1/4 I.D M Fastener Strip (4 ) 19 1 Adhesive Foam (6 ) 20 1 TRD ECU 21 1 TRD ECU Adapter & Harness 22 1 TRD Thermostat Page 2 of 20

3 Section II Mechanical Installation 1. Disconnect the negative battery terminal. 2. Remove the intake tube between the air cleaner assembly and throttle body (Figure 1). NOTE: Keep track of what lines are connected to them, as they will be reinstalled. 3. Remove the 3 bolts and air cleaner assembly (Figure 2). The bolts and air cleaner assembly will be reused. Figure 1 Figure 2 4. Remove the EGR block-off plate from the TRD supercharger (Figure 3). It will not be reused. 5. Remove the nuts and studs from the TRD supercharger. The studs will not be reused but the nuts will. Remove Figure 3 Page 3 of 20

4 6. Install the studs (1-5/8 ) supplied in the kit (Figure 4). Torque them to 14 ft-lbs. Place the supplied gasket over the studs. 7. Unclip the plastic wire loom housing from the rear of the passenger side of the engine (Figure 5). Figure 4 Remove from clip 8. Remove the 6mm bolt holding the plastic wire loom housing from the back of the supercharger (Figure 6). Figure 5 Bolt removed Figure 6 Page 4 of 20

5 9. Remove the factory banjo bolt from the end (firewall side) of the fuel line on the passenger side (Figure 7). The bolt will be reused. NOTE: The fuel rail is full of fuel and it will run out so take precautions to absorb it. Remove bolt 10. Pass the TRD-supplied double banjo bolt through 1 crush washer, the TRD fuel injection supply hose banjo fitting, a second crush washer, the factory banjo (with hard fuel line) and a third crush washer. Thread the TRD double banjo bolt into the fuel rail. See Figure 8 for exploded detail. NOTE: Do not fully tighten at this time. 11. Install the fuel injector block gasket and block onto the supercharger. The electrical connector of the injector should be up and the fuel supply banjo fitting hole facing down. Torque the nuts removed in step 4 to 14 ft-lbs. 12. Attach the remaining end of the TRD fuel injection supply hose by passing the factory banjo bolt removed in Step 9 through 1 crush washer, the TRD fuel injection supply hose banjo fitting, and 1 remaining crush washer. Thread the banjo bolt into the fuel injector block (Figure 9). NOTE: If the supercharger was installed prior to the this installation and the factory banjo bolt is no longer available a replacement can be ordered from TRD using part number TRD double Banjo bolt Figure 7 Fuel Supply hose Figure 8 Figure 9 Factory banjo Page 5 of 20

6 13. Tighten all of the fittings TRD double banjo bolt and both ends of the fuel line. NOTE: Make sure the factory banjo tab is oriented against the fuel rail tab (Refer to Figure 10). 14. Reinstall the 6mm bolt removed in Step 8 on Page 4 (Refer to Figure 6 on Page 4). 15. Clip the wire harness loom housing to the engine (Refer to Figure 5 on Page 4). NOTE: The clip may have to be adjusted towards the firewall to allow clearance for the loom housing and the banjo bolt head. Factory Banjo Installed IF THE VEHICLE HAS A TRD BOOST GAUGE INSTALLED, PROCEED TO STEPS 19 THROUGH 21, IF NO BOOST GAUGE IS INSTALLED, PROCEED TO STEPS 16 THROUGH 19. Figure 10 VEHICLE WITHOUT BOOST GAUGE Steps 16 to 21: 16. Remove the hose from the factory fuel pressure regulator (A) and the brass fitting (B) on the back of the supercharger (arrows A & B, Figure 11). The hose will not be reused. B A (Attach 6.8mm end of TRD hose here) Figure 11 Page 6 of 20

7 17. Remove the brass fitting of Step 17 from the supercharger and insert the TRD-supplied brass plug (arrow, Figure 12). Use Teflon thread sealant. 18. Install the small end of the TRD-supplied 6.8mm/9.5mm O.D. vacuum hose to the fuel pressure regulator. See Figure 12. Leave the other end loose for now. Go to step 23. VEHICLE WITH BOOST GAUGE: 19. Disconnect the boost gauge line NPT fitting from the brass T on the rear of the supercharger (Figure 13). Remove the brass T fitting. It will not be re-used. Then remove the hose and brass fitting from the rear of the supercharger. 20. Insert the included 1/8 NPT nipple into the supercharger where the brass fitting was removed. Use Teflon thread sealant. Attach the boost gauge line to the fitting (Figure 14). 21. Install the small end of the TRD-supplied 6.8mm/9.5mm O.D. vacuum hose to the fuel pressure regulator. See Figure 13. Leave the other end loose for now. Go to step 23. Brass T Fitting Figure 12 Attach 6.8mm end of TRD hose here Brass Fitting Attach 6.8mm end of TRD hose here Figure 13 Boost gauge line to 1/8 NPT Page 7 of 20 Figure 14

8 22. Remove the 3 bolts (arrows) and 4 clips (circles) and pull back the passenger-side fender liner (Figure 15). Figure 15 Page 8 of 20

9 23. Remove the 2 bolts that hold the factory tube that feeds air to the air box (Figure 16). Remove the tube. Remove bolts & tube Figure From the engine bay, remove the 2 bolts that hold the intake elbow to the fender (Figure 17). Remove the elbow. Remove bolts & elbow 25. Install the TRD-supplied 3-1/4 I.D. hose to the factory air box with the supplied clamp (Figure 18). The edge of the hose should rest at the lip of the shoulder. 26. Reinstall the factory air box and intake tube. Figure 17 Hose at lip Figure 18 Page 9 of 20

10 27. Route the TRD-supplied 6.8mm/9.5mm (O.D.) vacuum hose under the throttle body and attach it to the muffler on the side of the factory air hose between the air cleaner assembly and the throttle body (Figure 19). Section III Thermostat Installation 1. Open the radiator petcock and drain the coolant into a clean pan. Close the petcock after the coolant has drained. 2. Remove the bolt from the oil dipstick relocation bracket (Figure 20). Attach 9.5mm hose here Figure 19 Remove bolt Figure Use a 3/8 ratchet to release the tension on the dynamic tensioner and remove the belt from the supercharger (Figure 21). NOTE: Do not remove the belt from the vehicle completely. 4. Remove the bolt from the dynamic tensioner and remove the assembly (Figure 21). Release tension Remove bolt Page 10 of 20 Figure 21

11 5. Remove the bolt and the dynamic tensioner mounting bracket (Figure 22). Remove bolt 6. Remove the 3 nuts, wire clamp, water inlet and thermostat from the water pump (Figure 23). Figure Install the TRD thermostat with the jiggle valve downward, at the 6 o clock position (Figure 24). 8. Install the water inlet and torque the 3 nuts to 14 ft-lb (Figure 24). Figure 23 Figure 24 Page 11 of 20

12 9. Replace the dynamic tensioner assembly and mounting bracket (Figure 25). Use thread locker (such as Loctite 262) on both bolts. Torque the upper one to 25 ft-lbs and the lower one to 40 ft-lbs. NOTE: Align the lower hole of the bracket first and tighten the upper bolt. Then put the tensioner in place. Be sure to place the belt as shown in the picture and the alignment stud of the tensioner in the hole of the mounting plate. Replace bolt 10. Release the tension on the dynamic tensioner and replace the drive belt (Refer to Figure 21 on Page 10 and see Figure 26). 11. Reattach the oil dipstick relocation bracket and torque the bolt to 10 ft-lbs (Refer to Figure 20 on Page 10). NOTE: Be sure to maintain proper dipstick tube seal at the oil pan. The rubber grommet at the end of the dipstick should be properly engaged. 12. Fill the cooling system with coolant removed in Step 1 on Page 10. Figure 25 Figure 26 Page 12 of 20

13 Section IV Electrical Installation 1. The negative battery cable should already be removed, but if it is not, remove it now. 2. Cut the factory wire tie at the end of the loom boot that is attached to the firewall on the passenger side of the vehicle (Figure 27). 3. Remove the loom from the loom clamp (Figure 27). Then remove the loom clamp bracket. 4. Remove the electrical tape from the boot (Figure 27). 5. Remove the 2 nuts retaining the boot to the firewall (Figure 27). 6. Remove the 2 screws and the glove compartment door (Figure 28). 7. Remove the 3 screws and the lower finish No. 2 panel (Figure 28). Unplug the glove compartment light. SC-4RN-015-B, SC-TAC-010-B Remove tape Remove 2 nuts Loom clamp Figure 27 Cut wire tie Figure Remove the air duct vent tube (Figure 29). 9. Create a wire feeding tool about 10 inches long out of a wire clothes hanger or similar material. This will be used to feed the wire from the harness boot in the engine bay into the passenger compartment near the factory ECM. Slide tube to the left Figure 29 Page 13 of 20

14 10. Using electrical tape, securely attach the loose ends (not the end with plugs) of the TRD injector wire harness to the feeding tool created in the previous step (Figure 30). 11. Feed the TRD injector wire harness through the wire harness sleeve in the engine bay starting at the engine and feeding through the firewall boot. 12. Now feed the wire through the firewall into the passenger compartment. 13. Continue feeding the wire into the passenger compartment until there is just enough to reach the 7 th injector plug (Figure 31). Only the injector plug will be used. Use the small wire tie to hold the other connector in a secure location. 14. Place the TRD-supplied ¼ loom wrap over the exposed wires and tape the ends. 15. Replace the 2 nuts that hold the boot retainer plate to the firewall (removed in Step 5 on Page 13, refer to Figure 27). Replace the loom clamp bracket. 16. Replace the electrical tape removed in Step 4 on Page 13 (Refer to Figure 27). 17. Replace the loom in the clamp (removed in Step 3 on Page 13, Refer to Figure 27). 18. Use the medium wire tie to replace the one removed in Step 2 on Page 13 (Refer to Figure 27). 19. The TRD ECU Harness is shown in Figure 32. The connectors are marked "P1" and "P2". Refer to the Figure as necessary. P2 P1 Injector Connector Figure 30 Figure 31 Ignition Power Wire Unused Connector Ground Page 14 of 20 Figure 32

15 20. Pry up the white pin-locking bar on the 31-way connector of the TRD ECU Harness (Figure 33). Lift Figure Insert the Pink wire of the TRD 7 th injector harness in the A2 (counting from the right) pin location on the 31-way connector of the TRD ECU Harness (Figure 34). Make sure you press it in until you hear a "click." 22. Insert the Black wire with White Stripe in the A6 pin location (Figure 34). 23. Insert the Black wire with Red Stripe in the A7 pin location (Figure 34). 24. Press the white pin-locking bar back into place (Refer to Figure 33). A7 A6 A2 Figure 34 Page 15 of 20

16 25. Solder the Red wire into the factory "Ignition On" wire (Black with Blue Stripe for 4Runner, Black with White Stripe for Tacoma) that terminates in the connector and pin of the Factory ECU as shown in Table 1 and Figures 35 and 36 (next page) RUNNER Table 1 Year Vehicle Connector-Pin Runner E Runner E Runner E Runner E Tacoma (CA-spec) E Tacoma E Tacoma E Tacoma E RUNNER Figure 35 Page 16 of 20

17 TACOMA 2002 TACOMA 2003 TACOMA Figure 36 Page 17 of 20

18 26. Plug the 2 connectors of the TRD ECU Harness into the TRD ECU (Figure 37). 27. Plug Connector P1 of the TRD ECU Harness (refer to Figure 32 on Page 14) into the P1 side of the TRD Harness Junction Box. 28. Plug Connector P2 of the TRD ECU Harness (refer to Figure 32 on Page 14) into the P2 side of the TRD Harness Junction Box. 29. Remove the left 2 factory connectors (E9 & E10 for 4Runner, E7 & E8 for Tacoma) from the factory ECM (Figure 38). 4RUNNER Figure 37 TACOMA Figure 38 Page 18 of 20

19 30. Plug the Factory E9 & E10 (4Runner) or E7 & E8 (Tacoma) connectors (Refer to Figure 38 on the previous page) into the P1 side of the TRD Harness Junction Box (Figure 39). NOTE: The TRD harness should be plugged into the P2 side for the TRD ECU. If it is not, do it now. CAUTION: Double check all harness connections. The P1 & P2 sides of the junction box are identical. Any incorrect connections will result in a no-start condition or incorrect vehicle operation. P1 Figure Place the TRD junction box next to the blower unit (Figure 40a). Use a large wire tie to hold it against the factory ECM bracket. NOTE: Be sure to allow clearance for movement of the air conditioning servomotor and linkage (Figure 40b). ECM bracket TRD ECU junction box AC motor arm & linkage Fresh air lever Figure 40a Figure 40b Page 19 of 20

20 32. Place 2 squares of adhesive padding and fastener tape on the TRD ECU as shown in Figure 41. NOTE: The TRD logo is up. Adhesive padding Fastener tape Figure Place 1 square of adhesive padding tape on the TRD ECU as shown in Figure 42. NOTE: The TRD logo is down. Adhesive padding 34. Place the TRD ECU on the side of the airbag canister as shown in Figure 43. NOTE: The plugs of the ECU face the firewall. 35. Attach the ground terminal of the TRD harness to the bolt shown in Figure Replace the air duct vent tube (Refer to Figure 29 on Page 13). 37. Replace the 3 screws and the lower finish No. 2 panel (Refer to Figure 28 on Page 13). Be sure to plug the glove compartment light back in. 38. Replace the 2 screws and the glove compartment door (Refer to Figure 28 on Page 13). 39. Replace the negative battery terminal. 40. Start the engine and check for leaks around the fuel rail, injector block and thermostat housing. Test-drive and check for leaks again. Page 20 of 20 Airbag canister Figure 42 TRD ECU Figure 43 Ground here

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