Toyota - FJ Cruiser - Workshop Manual - 2010 - 2020

TOYOTA FJ CRUISER / 4RUNNER 2010 - COLD AIR INTAKE 4.0L V6 (1GR) Roller Rocker Section I – Installation Preparation Part Number(s): PTR03-89100 Kit Contents Item # 1 2 3 4 5 6 7 Quantity Reqd. 1 1 1 1 1 1 1 Additional Items Required For Installation Description Air Filter (P/N: PTR43-00083) Upper Air Box Lower Air Box Hump Coupler Throttle Body Coupler Air Inlet Tube Air Flow Accelerator Hardware Bag Contents Item # 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Quantity Reqd. 1 1 2 1 1 1 1 2 1 1 3 3 1 1 2 Description #52 Hose Clamp #56 Hose Clamp #72 Hose Clamp Plastic Nipple, 1/8” Plastic Nipple, 5/8” Hose, 5/32” ID X 20” Convoluted Split Loom , 15” Air Box Clip Filter Minder Grommet Filter Minder Nylon Tie Strap, Tree Mount Nylon Tie Strap, 6” Bracket, Wire Harness Plug, Plastic Tree Clip Bolt, Socket M4 X 0.7 X 8mm Item # 1 Quantity Reqd. 1 1 Description Instructions C.A.R.B E.O. Decal FJ Cruiser: 2010 → 4Runner 2010→ Conflicts Note: None Recommended Sequence of Installation If any other accessories are to be installed, it is recommended they be installed in the order described below to ease installation and/or avoid redundant work. Item # Accessory *Mandatory Legend STO Blankets or Fender Covers Torque Specifications: Special Tools i. M8 Hardware: Tighten to 60 in. lbf. + 5 in. lbf. (6.7 Nm + 0.6 Nm). None Required Installation Tools Nut driver 10mm socket 12mm socket ¼” drive ratchet ¼” drive extension Phillips head screwdriver Screwdriver, std. Allen wrench Torque wrench STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury CRITICAL PROCESS: Proceed with caution to ensure a quality installation. GENERAL PROCESS: This highlights specific processes to ensure a quality installation. TOOLS & EQUIPMENT: This calls out the specific tools and equipment required for this process Please see page 17 for important “Care and Maintenance” information! Recommended Tools Safety Tools Vehicle Protection Description Blue Thread Locking Fluid General Applicability Literature Bag Contents Item # 1 2 Quantity Reqd. 1 8mm or 5/16” ¼” drive ¼” drive ii. M6 Hardware: Tighten to 40 in. lbf. + 5 in. lbf. (4.5 Nm + 0.6 Nm) 6” long #2 #2 3mm in. lbf. (0 – 120 in. lbf.) Special Chemicals iii. M4 Hardware: Tighten to 10 in. lbf. + 2 in. lbf. (1.1 Nm + 0.2 Nm) iv. Hose Clamp: Tighten to 30 in. lbf. + 5 in. lbf. (3.4Nm + 0.6 Nm) Glass cleaner Silicone spray lubricant Issue A: 6/27/2010 Page 1 of 18 pages DIO TOYOTA FJ CRUISER / 4RUNNER 2010 - Section I – Installation Preparation Issue A: 6/27/2010 Page 2 of 18 pages COLD AIR INTAKE 4.0L V6 (1GR) Roller Rocker DIO TOYOTA FJ CRUISER / 4RUNNER 2010 - Section II – Installation A. Check Kit Contents COLD AIR INTAKE 4.0L V6 (1GR) Roller Rocker 1. Check kit for contents and damage. B. Vehicle and Parts Preparation 1. Completely read instructions and familiarize yourself with the installation before beginning. 2. Open hood. STOP 3. Apply vehicle protection to prevent damage to painted surfaces. STOP 4. Remove negative battery cable from terminal. STOP 5. Prior to installation, make sure all parts of the Cold Air Intake are clean and free of debris. i. Fig. C 1 Blow out the inside of the tube and air box with compressed air. C. Remove Factory Components Operations Performed in the Engine Compartment 1. Remove engine cover. (Fig. C1) i. Lift front of cover off studs and pull forward to disengage rear mounts. 2. Disconnect the MAF plug and wire harness clip. (Fig. C2) Fig. C 2 3. Unclip the remianing wire harness clips. (Fig. C3) Fig. C 3 Issue A: 6/27/2010 Page 3 of 18 pages DIO TOYOTA FJ CRUISER / 4RUNNER 2010 - COLD AIR INTAKE 4.0L V6 (1GR) Roller Rocker Section II – Installation 4. Loosen the factory hose clamp at the throttle body with a 10mm socket and ratchet assembly. (Fig. C4) 5. Disconnect the crank case vent and remove the M6 bolt and vacuum line from the resonator. (Fig. C4) Vac. hose M6 Bolt Crank case vent Fig. C 4 6. Unclip and remove the air box top with the intake tube and resonators. Remove the OEM resonator mounting bracket.(Fig. C5) i. Remove the resonator bracket by removing one M6 bolt. (Fig. C5) Resonator bracket Release 4 clips Fig. C 5 7. Remove the OEM filter, and the three M8 bolts securing the lower air box to the wheel well. (Fig. C6) Fig. C 6 Issue A: 6/27/2010 Page 4 of 18 pages DIO TOYOTA FJ CRUISER / 4RUNNER 2010 - COLD AIR INTAKE 4.0L V6 (1GR) Roller Rocker Section II – Installation 8. Unwrap the electrical tape from the MAF sensor wire harness and remove the plastic clip. i. Unwrap electrical tape Take care not to damage any of the wires inside the wire harness. (Fig. C7) Remove plastic clip Fig. C 7 9. Remove the MAF sensor wires from the main wire harness loom. (Fig. C8) i. Bring the wires out of the split loom all the way back to the 90 deg. plastic clip as shown. (Fig. C8) MAF wires 90 deg. plastic clip MAF connector 10. Carefully cut around the main wire harness loom to allow the MAF wires to be routed out and install the supplied split loom on the MAF wires. (Fig. C9) i. Take care not to cut any wires. ii. Remove the 90 deg. plastic clip. iii. Tape the ends of the split loom with electrical tape to keep the loom in place. iv. Also tape the area where the MAF wires form a “T” with the main wire harness. Issue A: 6/27/2010 Fig. C 8 Electrical tape “T” MAF connector Fig. C 9 Page 5 of 18 pages DIO TOYOTA FJ CRUISER / 4RUNNER 2010 - Section II – Installation COLD AIR INTAKE 4.0L V6 (1GR) Roller Rocker D. Install TRD Air Intake 1. Install the provided bracket and tree mount zip tie as shown. (Fig. D1) i. Remove the M6 bolt and place the provided bracket on top of the OEM brackt. ii. Use the M6 bolt to secure both brackets. Bracket Tree mnt. zip tie Fig. D 1 2. Install 2 tree mount zip ties in the M8 bolt holes on top of the passenger side valve cover as shown. (Fig. D2) Tree mnt. zip tie Fig. D 2 3. Use the zip ties installed in the previous steps to secure the wiring as shown. (Fig. D3). i. Route the MAF wires under the other wires and attach with the tree mount zip tie installed in step D1. (Fig. D3) Route MAF wires underneath and secure Secure harness Fig. D 3 Issue A: 6/27/2010 Page 6 of 18 pages DIO TOYOTA FJ CRUISER / 4RUNNER 2010 - COLD AIR INTAKE 4.0L V6 (1GR) Roller Rocker Section II – Installation 4. Remove the 3 rubber gromets and sleeves from the OEM lower air box. (Fig. D4) i. Push the sleeve out first, then remove the rubber grommet. (Fig. D4) Grommet Sleeve Fig. D 4 5. Install the three OEM rubber grommets and sleeves as well as the two supplied air box clips, in the TRD lower air box. (Fig. D5) i. ii. Install the rubber grommet first, then push the steel sleeve into place. (Fig. D5) Install the air box clips by pulling straight up on the clips to engage the air box. (Fig. D5) Clips Grommets and sleeves For installation on 4Runner, continue to step D12 The following steps are for FJ Cruiser ONLY Fig. D 5 6. From under the passenger side front bumper, remove three screws holding the fender liner in place. (Fig. D6) Fig. D 6 Issue A: 6/27/2010 Page 7 of 18 pages DIO TOYOTA FJ CRUISER / 4RUNNER 2010 - Section II – Installation COLD AIR INTAKE 4.0L V6 (1GR) Roller Rocker 7. .From inside the wheel well, remove the clips and screws in the locations indicated to allow access to the area above the fender liner. (Fig. D7) Fig. D 7 8. Pull the inner fender liner out as shown to allow access to the area directly above the tire. (Fig. D8) 9. Remove the two M6 bolts holding the air inlet Fig. D 8 duct in place. (Fig. D9) Fig. D 9 Issue A: 6/27/2010 Page 8 of 18 pages DIO TOYOTA FJ CRUISER / 4RUNNER 2010 - COLD AIR INTAKE 4.0L V6 (1GR) Roller Rocker Section II – Installation 10. Remove the air inlet duct. (Fig. D10, D11) Fig. D 10 Air inlet duct Fig. D 11 11. Reinstall the fender liner. (Fig. D12) Fig. D 12 Issue A: 6/27/2010 Page 9 of 18 pages DIO TOYOTA FJ CRUISER / 4RUNNER 2010 - COLD AIR INTAKE 4.0L V6 (1GR) Roller Rocker Section II – Installation 12. Insert the air flow accelerator into the air intake hole in the inner fender as shown. (Fig. D13) i. Squish the air flow accelerator so that it fits through the hole. ii. The TRD Logo should be facing up and into the engine compartment. (Fig. D14) Fig. D 13 TRD logo Fig. D 14 13. Slide the neck of the lower airbox into the air flow accelerator and be sure that the tabs on the air box line up with the notches in the rubber part. (Fig. D15) Fig. D 15 Issue A: 6/27/2010 Page 10 of 18 pages DIO TOYOTA FJ CRUISER / 4RUNNER 2010 - Section II – Installation COLD AIR INTAKE 4.0L V6 (1GR) Roller Rocker 14. Secure the TRD lower air box with the three M8 bolts removed in step C 7. (Fig. D16) i. 15. Clip the wire harness to the side of the lower air box as shown. (Fig. D17) Fig. D 16 Fig. D 17 16. Install the TRD air filter. (Fig. D18) i. OEM clip removed in step C8 Install the OEM clip removed in step C8 on the wire harness in the location shown. (Fig. D16) Press the air filter all the way down into the lower air box. (Fig. D18) Fig. D 18 Issue A: 6/27/2010 Page 11 of 18 pages DIO TOYOTA FJ CRUISER / 4RUNNER 2010 - Section II – Installation COLD AIR INTAKE 4.0L V6 (1GR) Roller Rocker 17. Insert the filter minder grommet into the air box lid as shown in the picture. A small amount of silicone spray, or similar lubricant may aid installation. (Fig. D19) Fig. D 19 18. Insert the filter minder into the grommet installed in step D17. i. Press the filter minder all the way down until it bottoms out on the grommet. A small amount of silicone spray, or similar lubricant may aid installation. (Fig. D20) Fig. D 20 19. Install the hump hose coupler onto the upper air box using the two #72 hose clamps. (Fig. D21) i. Slide the coupler all the way onto the neck of the air box until it bottoms out on the lip inside the coupler. Fig. D 21 Issue A: 6/27/2010 Page 12 of 18 pages DIO TOYOTA FJ CRUISER / 4RUNNER 2010 - COLD AIR INTAKE 4.0L V6 (1GR) Roller Rocker Section II – Installation 20. Install the upper air box by lowering the hinge side into place first. (Fig. D22) i. Make sure that the hinge pieces on the upper air box fully engage with the corresponding pieces on the lower air box. (Fig. D22) ii. To achieve propper fit, align the upper air box hinge pieces with the tabs on the lower air box, then slide toward the drivers side of the vehicle before rotating the Fig. D 22 upper air box down into position. (Fig. D22) Clips (2) 21. Secure the upper air box with the two clips installed in step D5. (Fig. D23) i. Make sure that the hinge side is fully engaged before attempting to close the clips. (Fig.D24) Fig. D 23 Hinge Fig. D 24 Issue A: 6/27/2010 Page 13 of 18 pages DIO TOYOTA FJ CRUISER / 4RUNNER 2010 - Section II – Installation COLD AIR INTAKE 4.0L V6 (1GR) Roller Rocker 22. Remove the MAF sensor from the OEM upper air box by removing the two philips head screws. (Fig. D25) i. Take care to not damage the sensor. 23. Install the MAF sensor and throttle body coupler onto the TRD intake tube. (Fig. D26) i. Install the MAF sensor with the two supplied M4 screws using a 3mm allen wrench. Take care to not damage the Oring on the sensor. ii. A small amount of blue thread locking fluid is recommended on the MAF screws to prevent them from loosening. iii. Slide the throttle body coupler onto the end of the TRD inlet pipe with a #52, and a #56 hose clamp. (Fig. D26) iv. With the hose clamps loose slide the coupler all the way onto the pipe as far as it will go. Use some silicone spray or similar lubricant to ease installation. (Fig. D26) Fig. D 25 #56 #52 Fig. D 26 2 24. Install the intake pipe assembly first into the coupler on the air box as shown. (Fig. D27) 1 Fig. D 27 Issue A: 6/27/2010 Page 14 of 18 pages DIO TOYOTA FJ CRUISER / 4RUNNER 2010 - COLD AIR INTAKE 4.0L V6 (1GR) Roller Rocker Section II – Installation 25. Rotate the intake pipe assembly down into positon, and slide the throttle body coupler on to the throttle body. (Fig. D28) i. Slide the T.B. coupler all the way out until it hits the stops. (Fig. D28) 26. Install the two supplied plastic nipples into the T.B. coupler, and connect the OEM crank case vent hose. (Fig. D29) i. Fig. D 28 Clock the T.B. coupler so that there is clearance between the crankcase vent hose, and the intake manifold. (Fig. D29) 1/8” plastic nipple 5/8” plastic nipple 27. .Replace the OEM vacuum hose with the longer one supplied in the kit. (Fig. D30) i. ii. Connect the vaccuum hose between the fuel pressure regulator and the small plastic nipple on the T.B. coupler. Secure the hose to the wire harness as shown using the supplied nylon tie strap (Fig. D30) Fig. D 29 Zip tie Supplied vac. hose Adjust the positioning of the intake tube until proper fit is achieved, then tighten all four hose clamps. (Fig. D30) Fig. D 30 Issue A: 6/27/2010 Page 15 of 18 pages DIO TOYOTA FJ CRUISER / 4RUNNER 2010 - Section II – Installation COLD AIR INTAKE 4.0L V6 (1GR) Roller Rocker 28. Plug in the MAF sensor and do a final check that all hose clamps and hardware are tight. (Fig. D23) 29. Install the supplied plastic plug in the hole in the front of the lower air box as shown. (Fig. D32) Fig. D 31 Plastic plug 30. Do a final check over, and ensure that all Fig. D 32 hoses and wires are secure. Then install the engine cover by engaging the rear mounts, and rotating it down and snapping it onto the front mounts. (Fig. D33) 31. Re-install negative battery cable to negative terminal. Tighten nut to 36 in. lbf. + 4 in. lbf. (4.0 Nm + 0.4 Nm) 32. Installer – The installation manual contains important “Care and Maintenance” information. Place the entire instruction manual in the glove box for owner’s future reference. Issue A: 6/27/2010 Fig. D 33 Page 16 of 18 pages DIO TOYOTA FJ CRUISER / 4RUNNER 2010 - COLD AIR INTAKE 4.0L V6 (1GR) Roller Rocker Section III – Care and Maintenance Air Filter Maintenance Service Intervals: Your TRD Cold Air Intake System has an air filter restriction gauge that indicates when the air filter needs service. When the air filter restriction gauge yellow indicator reaches the service filter lettering, use TRD's filter cleaning system (Toyota p/n PTR4300088) to service filter and maintain optimum performance. Do not over-oil the filter. This could contaminate the MAF sensor and cause the MIL (Malfunction Indicator Lamp) to illuminate and require non-warrantable repairs. Caring For The Finish On Your TRD Cold Air Intake. TRD intake systems have a natural finish on the tube and air filter housing. To clean your TRD intake system, simply spray with window cleaner and wipe with a soft, clean terry-cloth towel. NEVER use harsh chemicals or metal polish on TRD intake systems. Harsh chemicals and metal polishes will permanently damage the finish. How to read your air filter restriction gauge: New Filter Partially Dirty Filter (Do Not Clean Now) Service Filter Now Push To Reset Issue A: 6/27/2010 Page 17 of 18 pages DIO TOYOTA FJ CRUISER / 4RUNNER 2010 - COLD AIR INTAKE 4.0L V6 (1GR) Roller Rocker Section IV – Trouble Shooting Check: Accessory Function Checks Look For: Start the vehicle. o Full engagement of MAF sensor connector. If after you start the vehicle, or while driving, you encounter a Malfunction Indictor Lamp (MIL), check the following: o Tightness of all clamps. o Correctly installed valve cover breather hose. o Over-oiled air filter. o Clean the air filter as indicated in the TRD Filter Cleaning Kit and apply the proper Over-oiled Air Filter: amount of oil. o Replacement (non-warrantable) of the MAF sensor may be required. Vehicle Function Checks Start the vehicle o Contact your Toyota dealer as soon as If the lamp will not go off even after possible. checking and/or repairing any of the above: Issue A: 6/27/2010 Page 18 of 18 pages DIO