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.
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 00602-17620-155.
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. 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. 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.
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.
23. Remove the 2 bolts that hold the factory tube that feeds air to the air box (Figure 16). Remove the tube.
24. From the engine bay, remove the 2 bolts that hold the intake elbow to the fender (Figure 17). Remove the 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.
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).
3. 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).
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.
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.
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.
8. 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.
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 7th 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.
20. Pry up the white pin-locking bar on the 31-way connector of the TRD ECU Harness (Figure 33).
21. Insert the Pink wire of the TRD 7th 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).
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).
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.
31. 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).
