Toyota pmn Manuel d'utilisateur

1INSTALLATION INSTRUCTION MANUALISS REVISION RECORD DATE REVR.0 NEW Oct. 05 1.01 Revision Oct. 05 1.1ATTENTIONRead this installation instruction manua

101.2. HEAT SHIELD4-14-110-310-310-610-610-610-610-110-410-410-410-510-510-510-810-84-410-24-1

111.3. EXHAUST MANIFOLD4-24-14-34-33-79-39-39-39-39-39-29-14-14-1

121.4. INTERCOOLER8-68-18-58-38-56-46-26-46-16-58-47-77-27-57-77-37-67-77-47-87-67-56-47-16-36-48-28-4

131.5. AIR INTAKE25-125-12-21-125-225-42-92-112-102-512-112-32-102-1012-42-62-72-72-812-417-62-12-41-22-112-125-325-3

141.6. OIL FILTER13-213-313-313-113-413-426-715-215-315-315-113-1

151.7. OIL PAN AND BRACKETS27-114-214-714-114-614-514-619-120-320-120-25-15-45-55-35-25-65-519-2

161.8. ELECTRIC COMPONENTS24-824-824-824-323-92x23-815x23-424-724-224-923-523-223-123-635-124-624-923-524-624-724-215A

171.9. COOLING FAN22-322-222-322-322-322-422-422-422-423-324-1024-424-524-1124-1124-122-124-10

181.10.TEMPLATES27-227-421-121-321-227-127-521-53x21-53x21-43x21-43x27-32-12Cutting lines for hose

191.11.HEAT INSULATION, STICKERS AND SPARKPLUGS26-111-126-211-211-211-211-2

2

202. Parts ListNo. PART NAME QTY PART No. REF1.0 KIT, AIRBOX 1 AM300-324001-1 Bellow with spring clamps 1 AM183-170001-2 Airfilter, sport 1 AM181-5000

217.0 KIT, INTERCOOLER 1 AM300-330007-1 Intercooler 1 AM181-820007-2 Bracket, intercooler, No.1 1 AM300-276007-3 Bracket, intercooler, No.2 1 AM300-27

2214-4 Pipe, oil runback 1 AM869-7900014-5 Hose, connection to oil pan 1 AM869-8000014-6 Hose clamp 16-25 2 AM300-2710014-7 Gasket 2 90430-1203114-8 S

2323-3 Sensor, Temperature 1 AM300-3040023-4 Power Control unit 1 AM300-3100023-5 Relay 2 AM300-3190023-6 Fuse, 15 Ampere 1 AM300-3460023-7 Arma Flex

243. Specified torquePart tightenedTorque specificationNm kgcm ft.lbfHarness fixation clamp 3 30 2.2Oil return adapter 45 460 33Oil change plug 37 370

25Exhaust pipe onto turbo 16 160 11.5Oil return pipe 20 200 15Ground bolt 9 90 6.6Cooling fan cover 6 60 4.4Lambda sensor No. 1 44 450 32Exhaust manif

26INSTALLATION PROCEDURES1. Introduction1.1. SI UNIT.The UNITS given in this manual are primarily expressed according to the SI (international System

271.5. AIR HOSE AND CLAMP.NOTICE: – Follow the instructions below. Otherwise the hose may come off or intake air may leak, disabling driving due to en

282. Parts to be removed (see workshop manual for detailed instructions)U

29UUCONTINUED

3TABLE OF CONTENTSTABLE OF CONTENTS ...

303. Vehicle preparation1. REMOVE CARBON CANISTER.(a) Remove the clamp of the vacuum hose.R: Clamp(b) Disconnect the vacuum hoses from the carbon cani

313. HOLE PREPARATION.(a) Drill the hole out to 11.2 mm.(b) Remove burrs and protect the hole with anti-corrosion primer.(c) Insert the steel jack nut

324. Airfilter box heat shield preparation1. PREPARATION HEAT SHIELD.(a) Mark the position where to cut by using the template.K: Template (27-2)(b) Re

335. Oil-sump preparation1. INSTALL OIL RETURN ADAPTER.(a) Mark the position of the oil return hose adapter.(b) Punch-mark the drilling position.(spot

346. Underbody protection preparation1. UNDERCOVER PREPARATION.(a) Remove the 10 pop-rivets from the undercover.(b) Remove from the bottom side (engin

35(j) Place the undercover on the floor (engine side facing down)(k) Remove drain plug cover.(l) Prepare the template.K: Template (27-1)(m) Fix the te

36(t) Install the aluminum bracket-spoiler onto the undercover with 3 aluminum jack nuts using the jack nut tool.(SST AM300-38300)K: Bracket spoiler (

377. Engine cover preparation1. ENGINE COVER PREPARATION.(a) Mark the position where to cut. Use template 27-3(b) Remove the marked part, use an air d

388. Cooling fan preparation1. INSTALL COOLING-FAN.(a) Position the cooling-fan on the bonnet cover.K: Cooling-fan (22-2)K: Bonnet cover (22-1)(b) Ins

399. Inlet pipe preparation1. INSTALL VACUUM HOSE ADAPTER.(a) Put Loctite 270 on the hose adapter. (b) Install the hose adapter into the inlet pipe.K:

410. Intercooler preparation ...

4010. Intercooler preparation1. INSTALL LOWER BRACKET.(a) Install the rubber mounting onto the intercooler with Loctite 243 and handtighten.K: Rubber

4111. Pre-catalyser heat shield preparation1. INSTALL PRE-CATALYSER HEAT SHIELD.(a) Install the heat shield with the 2 clamps and 4 bolts onto the cat

4212. Turbo control system preparation1. TURBO CONTROL SYSTEM PREPARATION.(a) Install the power control-unit onto the bracket using the 2 bolts and 2

4313. Turbo preparation1. TURBO PROTECTION.CAUTION: Cover all the inlet and outlet holes with protective tape to avoid parts from falling in.2. REMOVE

445. INSTALL WATER OUTLET HOSE.(a) Install the outlet hose onto the outlet adapter.K: Water outlet hose (17-1)Torque: 14 NmNOTICE: Ensure that the con

459. INSTALL PRESSURE ACTUATOR HOSE.(a) Insert the pressure hose into the heat protection hoseK: Pressure hose (18-2)K: Hose Heat protection (18-1)(b)

4614. Installation engine compartment1. INSTALL EXHAUST MANIFOLD GASKET.(a) Place the new gasket onto the cylinder head studs.K: Gasket (9-2)2. INSTAL

475. INSTALL TURBO CHARGER BRACKET.(a) Install the bracket with short bolt and washer to the engine (hand tighten).K: Bolt (5-4)K: Washer (5-5)K: Brac

48(f) Install hose on engine side with a clamp.R: ClampTorque: 3 Nm8. INSTALL WATER OUTLET CONNECTIONS.(a) Install the clamps on the water outlet hose

4915. Installation engine compartment lower1. APPLY LIQUID GASKET TO OIL PAN.(a) Apply the liquid gasket onto the clean sump surface.NOTICE: Liquid ga

517. Install interior compartment ...6

505. INSTALL OIL PRESSURE SWITCH.(a) Install the oil pressure switch into the adapter using Loctite 243. Use SST 09816-30010R: Pressure switchTorque:

518. INSTALL OIL PRESSURE TUBE.(a) Install the oil pressure tube onto the inlet pipe using the clamps.K: Clamp (2 pcs.) (13-4)9. INSTALL INTERCOOLER O

52(h) Tighten the Intercooler fixation bolts.Torque: 1. Bolt 16 Nm2. Bolt 16 Nm3. Nut 12 Nm4. Nut 12 Nm5. Nut 12 Nm6. Bolt 12 NmNOTICE: When applying

5316. Installation engine compartment upper1. INSTALL TURBO INLET PIPE.(a) Position the turbo inlet pipe, hose and 2 clamps.K: Pipe, Airbox turbo (2-2

54KCutting lines for hoseRKKKRK(d) Wrap the T-junction with the anti-rattle foam.K: Anti-rattle foam (25-4).5. MODIFY ENGINE VENTILATION HOSE.(a) Modi

558. INSTALL VSV CONNECTIONS.(a) Install the vacuum hose 1 onto the VSV. 9. INSTALL AIR FILTER.(a) Remove the air filter from the air filter box.U: Ai

5612. INSTALL EXHAUST PIPE PRE-CATALYSER.(a) Position the exhaust pipe next to the turbo outlet side.K: Exhaust pipe pre catalyser (10-1)(b) Install t

5715. INSTALL OIL RETURN HOSE.(a) Install the oil return hose onto the oil return pipe and oil pan adapter using 2 clamps.K: Clamp (2 pcs.) (14-6)K: O

58 (j) Route the harness branch with the ground connection towards the original ground connection bolt.(k) Install the ground connection.Torque: 9 Nm(

5918. INSTALL LAMBDA SENSOR NO. 1(a) Install the lambda sensor into the exhaust manifold.R: Lambda sensor.Torque: 44 Nm19. INSTALL EXHAUST MANIFOLD HE

6PRECAUTIONSPLEASE READ THOROUGHLY THESE PRECAUTIONS BEFORE INSTALLING THE CHARGER KITDo not pinch the rear wring or harness in the tightenedpart.When

60(b) Install the lambda sensor harness with the clip into the bracket.K: Clip (19-1)21. SPARK PLUG EXCHANGE(a) Remove the 4 bolts of the coils.R: Bol

6117. Install interior compartment1. INSTALL CONTROL-UNIT ASSEMBLY. (MANUAL TRANSMISSION ONLY)(a) Install the control-unit assembly onto the studs usi

624. INSTALL GROUND CONNECTION.(a) Remove the original ground bolt.(b) Install the ground point onto the bolt.(c) Install the ground bolt.Torque: 9 Nm

6318. Parts to be installed (see workshop manual for detailed instructions)K20-4

64CONTINUED

7PREPARATION1. SST (Special Service Tools)2. Lubricants / Liquids1 09032-00100 Oil pan remover2 09228-06501 Oil filter wrench3 09816-30010 Oil pressur

8VEHICLE LIFT LOCATIONSIn this manual, a plate type or swing arm lift is recommended. See the description below for details of the supporting and atta

9PARTS1. LocationNumbers with a character (Ex. 14-1) in “PARTS LOCATION” correspondent to numbers in the text and the illustration in “INSTALLATION PR