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Toyota 1ZZ-FTE, Installation Instructions Manual

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Toyota 1ZZ-FTE Installation Instructions Manual Download Page 25

25

Exhaust pipe onto turbo

16

160

11.5

Oil return pipe

20

200

15

Ground bolt

9

90

6.6

Cooling fan cover

6

60

4.4

Lambda sensor No. 1

44

450

32

Exhaust manifold heat shield

20

200

15

Lambda sensor No. 2

44

440

32

Spark plugs

25

250

17.9

Ignition coils

9

90

6.6

Control-unit assembly (manual)

13

130

9.3

Control-unit assembly (automatic)

13

130

9.3

Automatic control unit

13

130

9.3

Wiring harness ground connection

9

90

6.6

Summary of Contents for 1ZZ-FTE

Page 1: ...ual 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 TOYOTA MOTORSPORT GMBH LHD RHD TURBO KIT MR 2 1ZZ FTE ...

Page 2: ...2 ...

Page 3: ... Water hose and clamp 26 1 5 Air hose and clamp 27 1 6 Oil and coolant 27 2 Parts to be removed see workshop manual for detailed instructions 28 3 Vehicle preparation 30 1 Remove carbon canister 30 2 Remove harness clamps 30 3 Hole preparation 31 4 Harness fixation 31 5 Harness grommet hole interior 31 4 Airfilter box heat shield preparation 32 1 Preparation heat shield 32 5 Oil sump preparation 3...

Page 4: ...ttle body housing 48 15 Installation engine compartment lower 49 1 Apply liquid gasket to oil pan 49 2 Install oil pan 49 3 Install oil pressure switch extension 49 4 Install oil pressure switch extension bolt 49 5 Install oil pressure switch 50 6 Install Intercooler 50 7 Install intercooler inlet pipe 50 8 Install oil pressure tube 51 9 Install intercooler outlet pipe 51 16 Installation engine co...

Page 5: ...ssion 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 Parts to be installed see workshop manual for detailed instructions 63 ...

Page 6: ... or a broken wire harness After installation check that all the functions of the car are normal Be sure to disconnect the negative lead from the battery terminals Protect the car with fender covers and so on Use the correct tool when tightening bolts and nuts After fastening band clamps cut away all the excess of the clamps Be sure to firmly tighten connectors and terminals Before connecting the p...

Page 7: ...9228 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 conserving or ILSAC multigrade engine oil Refer to the owners manual for the viscosity to recommend 0W 40 ...

Page 8: ...ption 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 attachment lower ends A B c Align the attachment upper end with the rocker flange front notch Swing arm type lift C A B ...

Page 9: ...S 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 14 3 14 4 17 7 16 4 17 3 17 2 17 3 ...

Page 10: ...10 1 2 HEAT SHIELD 4 1 4 1 10 3 10 3 10 6 10 6 10 6 10 6 10 1 10 4 10 4 10 4 10 5 10 5 10 5 10 8 10 8 4 4 10 2 4 1 ...

Page 11: ...11 1 3 EXHAUST MANIFOLD 4 2 4 1 4 3 4 3 3 7 9 3 9 3 9 3 9 3 9 3 9 2 9 1 4 1 4 1 ...

Page 12: ...12 1 4 INTERCOOLER 8 6 8 1 8 5 8 3 8 5 6 4 6 2 6 4 6 1 6 5 8 4 7 7 7 2 7 5 7 7 7 3 7 6 7 7 7 4 7 8 7 6 7 5 6 4 7 1 6 3 6 4 8 2 8 4 ...

Page 13: ...13 1 5 AIR INTAKE 25 1 25 1 2 2 1 1 25 2 25 4 2 9 2 11 2 10 2 5 12 1 12 3 2 10 2 10 12 4 2 6 2 7 2 7 2 8 12 4 17 6 2 1 2 4 1 2 2 1 12 1 25 3 25 3 ...

Page 14: ...14 1 6 OIL FILTER 13 2 13 3 13 3 13 1 13 4 13 4 26 7 15 2 15 3 15 3 15 1 13 1 ...

Page 15: ...15 1 7 OIL PAN AND BRACKETS 27 1 14 2 14 7 14 1 14 6 14 5 14 6 19 1 20 3 20 1 20 2 5 1 5 4 5 5 5 3 5 2 5 6 5 5 19 2 ...

Page 16: ...16 1 8 ELECTRIC COMPONENTS 24 8 24 8 24 8 24 3 23 9 2x 23 8 15x 23 4 24 7 24 2 24 9 23 5 23 2 23 1 23 6 35 1 24 6 24 9 23 5 24 6 24 7 24 2 15A ...

Page 17: ...17 1 9 COOLING FAN 22 3 22 2 22 3 22 3 22 3 22 4 22 4 22 4 22 4 23 3 24 10 24 4 24 5 24 11 24 11 24 1 22 1 24 10 ...

Page 18: ...18 1 10 TEMPLATES 27 2 27 4 21 1 21 3 21 2 27 1 27 5 21 5 3x 21 5 3x 21 4 3x 21 4 3x 27 3 2 12 Cutting lines for hose ...

Page 19: ...19 1 11 HEAT INSULATION STICKERS AND SPARKPLUGS 26 1 11 1 26 2 11 2 11 2 11 2 11 2 ...

Page 20: ...00 3 2 Rod End 1 AM300 34700 3 3 Actuator 1 AM300 34800 3 4 Nut Actuator 2 AM300 34900 3 5 Nut Rod End 1 AM300 35600 3 7 Gasket turbo charger casting 1 AM182 82000 4 0 KIT TURBO CHARGER FIXING NO 1 1 AM300 32700 4 1 Bolt hex head M8X30X1 25 6 AM300 25200 4 2 Bolt hex head M8X25X1 25 1 AM901 40000 4 3 Locking Plate No 1 2 AM300 25300 4 4 Locking Plate No 2 1 AM182 92000 5 0 KIT TURBO CHARGER FIXING...

Page 21: ...ERTER 1 AM300 33300 10 1 Pipe with pre catalyser 1 AM182 77000 10 2 Heat shield No 2 1 AM182 90000 10 3 Bracket heat insulation 2 AM300 24300 10 4 Bolt hex head M10X40X1 25 3 90105 10227 10 5 Nut hex head M10X1 25 3 90177 10001 10 6 Bolt hexagon socket M6X16X1 4 AM300 24600 10 7 Gasket exhaust pipe 1 17451 22060 10 8 Gasket exhaust pipe 2 90917 06065 11 0 KIT HEAT INSULATION 1 AM300 33400 11 1 Hea...

Page 22: ... protection 1 AM901 84000 18 0 KIT ACTUATOR 1 AM300 34100 18 1 Hose Heat protection 1 AM300 27500 18 2 Hose Actuator turbo 1 AM182 65000 18 3 Hose clamp 10 16 2 AM300 00400 19 0 KIT FIXING AIR FUEL SENSOR 1 AM300 34200 19 1 Cable clip 2 AM300 27000 19 2 Cable fixing bracket No 1 1 AM182 80000 20 0 KIT FIXING TAIL LIGHT 1 AM300 34300 20 1 Clamp Multifix 1 AM300 24800 20 2 Bolt hex head M6X16X1 0 1 ...

Page 23: ...11 Capnut for temperature sensor Bracket 2 90176 06045 24 12 Clip Bonnet insulation 3 90467 10018 24 13 Clip Bonnet cover 1 90467 07155 25 0 KIT HOSE CONNECTION POWER CONTROL 1 AM300 37700 25 1 Hose Boost pressure 1 AM300 37400 25 2 T junction Connector 1 AM300 37300 25 3 Hose clamp 10 16 Air connection 2 AM300 04000 25 4 Foam tape 1 AM300 37500 26 0 KIT SPAREPARTS NO 1 AM300 37900 26 1 Sticker RO...

Page 24: ...0 14 3 Turbo charger bracket bolt turbo charger engine 16 160 11 5 Hose turbo inlet side clamps 3 30 2 2 Hose turbo engine side clamps 3 30 2 2 Water outlet clamps 3 30 2 2 Blind cap throttle body 9 90 6 6 Oil pan 9 90 6 6 Oil pressure switch adapter 13 130 9 3 Oil pressure switch adapter bolt 20 200 14 3 Oil pressure switch 13 130 9 3 Intercooler inlet pipe clamps 3 30 2 2 Intercooler inlet pipe ...

Page 25: ...0 4 4 Lambda sensor No 1 44 450 32 Exhaust manifold heat shield 20 200 15 Lambda sensor No 2 44 440 32 Spark plugs 25 250 17 9 Ignition coils 9 90 6 6 Control unit assembly manual 13 130 9 3 Control unit assembly automatic 13 130 9 3 Automatic control unit 13 130 9 3 Wiring harness ground connection 9 90 6 6 ...

Page 26: ...t or parts that has have been removed from the vehicle and will be Reused for installation or assembly 1 4 WATER HOSE AND CLAMP NOTICE Follow the instructions below Otherwise the hose may come off or the coolant may leak from the connection resulting in engine overheat Paint mark 3 5mm 3 5mm Example a When fitting the hose mixture of water and L L C 50 50 to 100 0 can be used for lubrication b The...

Page 27: ...f the pipe for fitting b When fitting the hose to the pipe make sure to push in the hose until it reaches the paint mark If there is no paint mark on the pipe push the hose to the end c Unless otherwise specified in this manual fit the hose clamp at 3 to 5 mm 0 118 to 0 197 In from the end of the hose HINT Do not wrap the hose clamp around the hose at a slant d When tightening the hose clamp check...

Page 28: ...28 2 Parts to be removed see workshop manual for detailed instructions U ...

Page 29: ...29 U U CONTINUED ...

Page 30: ...SS CLAMPS a Cut the harness clamp A from the harness U Harness clamp b Reposition the harness B c Reinstall the carbon canister d Reconnect the carbon canister hoses with the clamp e Fix the harness to the carbon canister clip C f Remove the harness clamp out of the body panel U Harness clamp g Remove the plastic plug from the body panel U Plug h Reposition the harness clamp E N G IN E O IL R R A ...

Page 31: ...harness K Harness clamp 20 1 b Mount the clamp with 1 bolt and bracket into the jack nut K Bolt 20 2 K Bracket No 1 19 2 Torque 3 Nm 5 HARNESS GROMMET HOLE INTERIOR a Mark the position where to drill b Drill a 27 mm hole using a special hole saw NOTICE Ensure that all harness and vehicle components in the interior AND engine compartment are moved aside to avoid damage during drilling c Remove burr...

Page 32: ...n 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 K ...

Page 33: ...he nut and copper gasket and Loctite No 270 K Adapter 14 1 K Nut 14 2 K Copper gasket 14 7 Torque 45 Nm h Install the oil drain plug with a new gasket K Gasket 14 7 R Oil drain plug Torque 37 Nm 2 CLEANING a Remove all liquid gasket remains from the contact surface b Clean the oil sump in a parts wash system to ensure all gasket and drilling particles are removed NOTICE Check if the gasket contact...

Page 34: ...ent out of the sound insulation NOTICE Before removing the plastic reinforcement cut it with scissors c Fix the template to the undercover with tape K Template 27 4 d Mark the position where to cut e Cut the marked position f Remove the template g Turn the cover with the engine side facing up h Mark the position of the sound insulation where to cut i Cut the marked position ...

Page 35: ...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 Remove the template q Pre drill 6 holes of 4mm r Drill the 6 x 11 2 mm holes into the undercover s Cut the marked position out of the undercover with a cutting tool U K Ø 4 mm 6x Ø 11 5 mm ...

Page 36: ...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 K Aluminum jack nut 3 pcs 21 4 K Jack nut tool 26 8 v Install the aluminum air guide bracket onto the undercover brackets using 6 bolts K Air guide bracket 21 2 K Bolt 6 pcs 21 5 Torque 5 Nm K K K K K K K K 6x K K ...

Page 37: ...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: ...Torque 6 Nm NOTICE Ensure that the harness connection is facing the right direction 2 INSTALL BRACKET TO COVER a Install temperature sensor bracket to cover K Bracket 24 1 K Nut 2x 24 11 K Bolt 2 pcs 24 10 Torque 10 Nm 3 TEMPERATURE SENSOR a Install the temperature sensor into the bracket with a nut K Temperature sensor 23 3 K Washer 24 5 K Flat nut 24 4 Torque 20 Nm K 4x K K K 4x K 2x K 2x K K K ...

Page 39: ...nto 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 into the VSV bracket R VSV 3 INSTALL VSV a Install the VSV onto the inlet pipe with the bolt K Bolt 2 10 K Washer 2 9 K Nut 2 11 R VSV Torque 9 Nm K K Ø 6 5 mm R R K K K R ...

Page 40: ...No 1 7 2 K Nut 7 7 2 INSTALL UPPER BRACKET a Install the bracket 2 onto the intercooler with a bolt hand tighten while using Locktite 243 K Bracket Intercooler No 2 7 3 K Bolt 7 6 b Install the rubber mounting onto the bracket 2 with a nut and hand tighten while using Locktite 243 K Rubber mounting 7 5 K Nut 7 7 a Install the bracket 3 onto the rubber mount with a nut hand tighten while using Lock...

Page 41: ...e 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 the exhaust tube of 5 mm NOTICE Ensure location is parallel to flange K K K K 4x 2x 5 mm ...

Page 42: ...trol 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 K Relay 2pcs 23 5 K Bolt 2 pcs 24 9 K Nuts 2 pcs 24 6 Torque 6 Nm 2 INSTALL CONTROL UNIT HARNESS a Install the control unit harness into the control unit with the 2 connectors K Control unit wiring harness No 1 23 1 b Install the relay connectors into the relays K K K K K K K K K K K ...

Page 43: ...ge nut assurance 3 TURBO LUBRICATION a Insert some engine oil into the oil return outlet side of the turbo and rotate the turbo turbine axle a few times to lubricate the axle bearings CAUTION Close the inlet hole with tape to avoid parts from falling in 4 INSTALL WATER ADAPTERS a Install the water outlet 2 adapter 16 16mm K Outlet adapter No 1 17 4 Torque 70 Nm NOTICE The boss side of the adapter ...

Page 44: ...2 Nm NOTICE Ensure that the water inlet tube is pointing into the right direction 7 INSTALL OIL PRESSURE TUBE a Install the oil pressure tube with the screw and 2 copper seal rings K Oil pressure tube 13 1 K Screw 13 2 K Copper seal rings 2 pcs 13 3 Torque 25 Nm NOTICE Ensure that the connection is pointing into the right direction in line with turbo inlet housing 8 INSTALL PLATE WITH PRESSURE ACT...

Page 45: ... 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: ...37 Nm 3 POSITION TURBO CHARGER a Position the Turbo charger underneath the exhaust manifold K Turbo charger 3 1 b Position the gasket between the manifold and the Turbo charger K Gasket 3 7 NOTICE The embossed side of the gasket should face towards the exhaust manifold 4 INSTALL TURBO CHARGER a Install the 4 bolts with the locking plates hand tighten NOTICE The left front bolt is short 25 mm lengt...

Page 47: ...ten the bolt of the bracket to the Turbo charger Torque 20 Nm d Tighten the bolt of the bracket to the engine Torque 16 Nm 7 INSTALL WATER INLET CONNECTION a Remove the water hose clamps R Hose clamps 2 pcs b Remove the water hose R Water hose NOTICE Some coolant will flow out of the cooling system c Install additional Hose Heat Protection K Hose Heat Protection 17 7 d Install hose on turbo inlet ...

Page 48: ...the Turbo charger water tube and the engine water connection NOTICE ENSURE THAT THE CLAMP MECHANISM IS FACING DOWNWARDS TO AVOID DAMAGE TO THE INLET TUBE TO BE INSTALLED LATER 9 WATERHOSE FIXATION a Install the plastic clamp to fix the water outlet hose K Plastic clamp 16 4 10 INSTALL PROTECTION CAP THROTTLE BODY HOUSING a Install the blind cap on the throttle body housing with a clamp K Protectio...

Page 49: ...se Special tool SST 09816 30010 R Oil pressure switch b Install the oil pressure switch extension into the oil filter housing using Loctite 243 K Extension 15 2 Torque 13 Nm c Remove oil filter Use special tool SST 09228 06501 U Oil filter d Install a new oil filter K Oil filter 26 7 4 INSTALL OIL PRESSURE SWITCH EXTENSION BOLT a Route the oil pressure tube towards the adapter b Insert the hollow ...

Page 50: ...rbox side to fix the bracket hand tighten K Bolt 7 6 c Install the bolt M8 x 20 into the gearbox front to fix the bracket hand tighten K Bolt 7 8 7 INSTALL INTERCOOLER INLET PIPE a Position intercooler inlet pipe 2 hoses and 4 hose clamps K intercooler inlet pipe 6 1 K Hose turbo side 6 2 K Hose intercooler side 6 3 K Clamp 4 pcs 6 4 b Tighten outer hose clamps on turbo charger side and intercoole...

Page 51: ...p 2 pcs 8 4 b Tighten outer hose clamp on intercooler side Torque 3 Nm c Pull outlet pipe 5 mm out of the hose and hand tighten inner clamp d Position intercooler outlet pipe hose and 2 clamps K Hose throttle body side 8 3 K Clamp 2 pcs 8 5 e Tighten outer hose clamp on the throttle body side Torque 3 Nm f Pull outlet pipe 5 mm out of the hose and tighten inner clamp Torque 3 Nm g Install the plas...

Page 52: ... 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 i Tighten the inner clamp of the inlet pipe Torque 3 Nm 1 2 4 3 5 6 ...

Page 53: ...0 K Bracket 2 3 Torque 9 Nm b Position the bracket and fix the bracket to the cylinder head with a bolt washers and nut K Bolt 2 6 K Nut 2 8 K Washer 2 pcs 2 7 Torque 25 Nm c Tighten the inner clamp of the inlet pipe hose Torque 3 Nm 3 INSTALL WATER HOSE CLAMP a Install the water hose with the clamp to the turbo inlet pipe K Clip 17 6 4 INSTALL VSV T JUNCTION a Cut the vacuum hose 2 and insert the...

Page 54: ...e 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 R Ventilation hose K Clamp 12 1 Torque 3 Nm b Install distance clamp onto the hoses K Clamp 12 4 7 INSTALL ENGINE VENTILATION HOSE ONTO TURBO INLET PIPE a Install the ventilation hose onto the turbo inlet pipe with the hose clamp K Clamp 12 1 Torque 3...

Page 55: ...R a Install the bellow onto the air filter box cover using the spring clamp K Bellow with spring clamps 1 1 11 INSTALL AIR FILTER BOX COVER a Install the cover onto the air filter box b Install the bellow onto the turbo inlet pipe using the spring clamp c Close the 2 clamps of the air filter box d Connect the airflow meter connector e Install the harness clip to the side of the air filter box f In...

Page 56: ...b Install the exhaust pipe bracket using the bolts K Bracket 5 1 Torque 24 Nm NOTICE Temporarily install a bolt onto the bracket and exhaust flange for positioning the outlet pipe c Tighten the 3 exhaust bolts Torque 16 Nm d Bend the locking plates against the bolt heads to secure the bolts 14 INSTALL OIL RETURN PIPE a Install the oil return pipe onto the turbo charger using 2 bolts and a gasket K...

Page 57: ...wiring harness grommet into the bulk head hole Short end towards interior K Wiring harness No 2 23 2 d Install the cable tie wraps into the body holes K Tie wraps 2 pcs 23 9 e Route the harness branch with the eyelet towards the positive battery terminal following the original vehicle harness using the tie wraps K Tie wraps 5 pcs 23 8 f Route the other harness branch together with the vacuum hose ...

Page 58: ...cm using the tie wraps K Tie wraps 23 8 17 INSTALL COOLING FAN COVER a Install the cooling fan cover onto the engine bonnet using 4 bolts and a clip R Bolt 4 pcs K Clip 24 13 Torque 6 Nm K Cover 22 1 b Connect the wiring harness to the temperature sensor c Remove the plastic clip and position the vehicle and cooling fan harness behind the sound insulation d Install the sound insulation with the 2 ...

Page 59: ...the exhaust manifold heat shield onto the manifold using the 4 bolts K Heat insulation No 1 11 1 K Bolt 4 pcs 11 2 Torque 20 Nm b Connect the lambda sensor connector to the vehicle harness c Fix the sensor connector to the inlet pipe bracket 20 INSTALL LAMBDA SENSOR NO 2 a Install the lambda sensor into the exhaust manifold R Lambda sensor Torque 44 Nm R K K K K K R ...

Page 60: ...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 Torque 25 Nm e Install the ignition coils with 4 bolts R Bolts 4 pcs Torque 9 Nm K R R R R ...

Page 61: ...UTOMATIC TRANSMISSION CONTROL UNIT AUTOMATIC TRANSMISSION ONLY a Remove the 3 nuts b Remove the control unit and put it aside do not disconnect the connectors 3 INSTALL CONTROL UNIT ASSEMBLY AUTOMATIC TRANSMISSION ONLY a Install the control unit assembly onto the studs using a nut K Nut 24 8 Torque 13 Nm b Install the automatic control unit using the 3 nuts R Nut 3 pcs Torque 13 Nm K K K K R R R ...

Page 62: ... CONNECT WIRING HARNESS a Disconnect the 3 connectors of the engine ECU b Connect the turbo charger control unit harness to the engine ECU c Connect the 3 engine ECU connectors to the turbo charger control system harness d Connect the grey connector of the interior harness to the engine room harness e Connect the vacuum hose to the control unit ...

Page 63: ...63 18 Parts to be installed see workshop manual for detailed instructions K 20 4 ...

Page 64: ...64 CONTINUED ...

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