1995 – 2004 – 2RZ & 3RZ Low Boost Supercharger

Tools Needed:

• Basic Mechanics tools
• Metric Sockets, Allen & Open-End Wrench Sets
• Masking Tape for Labeling Hardware and Parts
• Electrical Tape
• Clean Work Bench
• Parts Tray
• Rags or Shop Towels
• Teflon Tape
• Red Loctite
• Safety Goggles
• Toyota Repair Manual

Accessories (Not included in this kit):

• Boost gauge (recommended)
• Spark plugs
• AFR Gauge
• Header, High flow Cat, Cat back Exhaust System

Installation Preparation:

1. Before you begin, we recommend that you thoroughly clean the engine and engine compartment. If you don't, grease buildup on parts could become dislodged during the procedure and fall into the engine.

2. Make sure the engine has cooled fully before beginning this installation.

3. To help you later, draw a diagram of your engine's vacuum hose routing before you disconnect anything. However, some of the vacuum connections on your intake manifold may not be the same as those on the supercharger. Study and closely follow the vacuum diagrams for your specific application included in the back pages of these instructions.

4. The LC Engineering supercharger kit has been designed to reuse most of the stock nuts and bolts. Therefore, as you remove them, keep them with their components or label them for location. This will assure a faster, easier installation.

Installation Instructions:

1. Disconnect the ground cable from the battery, and then the positive cable. Remove battery from the vehicle.

2. Remove air cleaner hose with resonator. ( See Figure 1)

3. Remove evaporation canister vacuum switch valve (VSV) hose.

4. Remove PCV hose.

5. Remove EGR modulator and hoses. NOTE: Take note of hose location and routing for re-installation. (Figure 2)

6. Disconnect power steering idle-up connector from the sensor and also the wiring from the intake manifold bracket. (See arrows in Figure 3)

7. Remove fuel pressure regulator hose from intake air connector.

8. Remove intake air connector. (Figure 4)

9.Disconnect Throttle Position Sensor (TPS) connector from TPS in throttle body.

10. Disconnect Idle Air Control (IAC) connector from IAC in throttle body. Disconnect coolant line from IAC. Pinch off coolant lines before EGR valve.

11. If vehicle is equipped with EGR, then disconnect EGR connector from EGR sensor in intake chamber. NOTE: If no EGR go to step 15.

12. Remove throttle body from intake manifold and set aside. (Figure 5)

13. Disconnect EGR feed tube at EGR valve. See "A" arrows in (Figure 6).

14. Disconnect EGR valve from intake chamber.

15. Remove wire harness bracket from backside of intake chamber. See arrow "B" in (Figure 6.) Remove bracket from wire harness.

16. Remove bolt from the upper side of the intake chamber bracket see arrow in (Figure 7). Loosen lower bolt from air intake chamber bracket.

17. Disconnect the DLC 1 from the bracket on the air intake chamber assembly. NOTE: 1995-2001 vehicles only.

18. Remove the wire harness bracket for the DLC 1 wiring from the air intake chamber assembly. 1995-2001 vehicles only.

19. Disconnect the brake booster vacuum hose from the intake chamber hose barb.

20. If your vehicle is equipped with EGR, then disconnect EGR tube bracket from the backside of the cylinder head.

21. Remove the 3 bolts and 2 nuts shown in (Figure 8).

22. Remove the air intake chamber and gasket. On vehicles with EGR.

23. Remove the injector wiring ground strap from the intake manifold.

24.HIGH BOOST ONLY! Remove the 2 bolts from the fuel return pipe and disconnect the fuel return hose from fuel pressure regulator. See (Figure 9). Caution: Plug fuel return hose so that no fuel will spill. Set pipe and hose aside.

25. Remove fuel pressure regulator from the fuel rail.

26. Disconnect wire loom clips from the intake manifold brackets and remove the clips from the wire loom. See arrows in (Figure 10).

27. On vehicles with EGR, remove the EGR vacuum switch valve bracket from the intake manifold.

28. Disconnect the camshaft position sensor connector. If equipped See (Figure 10).

29. Remove wire-loom bracket and clips from the wire loom that was disconnected in Step 15.

30. Disconnect the detonation sensor connector (A), and the crankshaft position sensor connector (B). See (Figure 11). Both connectors are located next to the engine block, and below the intake manifold.

31. Disconnect all four fuel injection connectors and set wiring aside.

32. On vehicles with EGR, remove the EGR coolant hose. Remove only the hose that runs down through the intake manifold runners. Plug hose so that coolant will not leak.

33. Disconnect the fuel inlet banjo fitting from the fuel rail. Remove both banjo washers. See (Figure 12).

34. Remove the intake manifold from the cylinder head. You will replace the gasket with the new one in the kit.

35. Remove the original equipment (OE) intake manifold chamber stay.

36. Remove the evaporative canister steel line that is secured to the top of the radiator fan shroud and set aside.

37. On 2000 and earlier model years, step 36 may not be necessary. Check the power steering pressure feed hose clearance to the supercharger by installing the supercharger main assembly onto the cylinder head. When installing the supercharger, the supercharger drive pulley and snout slides under the power steering pump return hose. If necessary, adjust the power steering line next to the banjo fitting on the power steering pump. See (Figure 13). The steel line needs to be parallel with the engine centerline. NOTE: Adjust carefully so the steel line will not kink. When adjusted correctly, the rubber hose that is connected to the steel line will have clearance to the supercharger housing and also to the lower radiator hose check and remove.

38. Attach the new supplied 2-piece lower manifold bracket to the engine mount with one 8mm x 25mm long flange head hex bolt See arrow in (Figure 14). Make sure the L-portion of the bracket is towards the front of the vehicle. (Figure 14) shows the chamber stay in the assembled position. Attach only the lower bolt in this step. Tighten bolt finger tight.

39. Remove the radiator fan shroud for easier access to the components in the following steps. See (Figure 15).

40. Remove power steering belt. See (Figure 16).

41. Remove the two bolts that secure the power steering pump to the pump bracket. See (Figure 18). power steering pulley dose not have to be removed accecss to the bolts is provided though the pulley holes.

42. Install the supplied idler pulley bracket to the front of the power steering pump. See (Figure 19). NOTE: Pulley is removed for photos only. Use (2) 10mm x 1.25 x 100mm long bolts supplied. Both bolts replace the OE bolts removed in Step 40. Torque bolts to 39 29 ft-lbs. NOTE: The idler pulley for the 3RZ should use the top hole. The 2RZ uses the lower hole.

43. If your vehicle has eight round intake ports in the cylinder head, then proceed with steps 43 and 44. NOTE: If your vehicle has four oval intake ports, then skip ahead to step 45.

44. The wires that connect to both the detonation sensor and the crankshaft position sensor need to be routed below the intake manifold. Remove the nylon split flexible tubing around the area where the wires join the main engine wire loom. See (Figure 23). Separate the detonation sensor and crankshaft position sensor wires back about 6" to 8" from the original breakout point. Use electrical tape to wrap the wires that have been split out from the main wire loom. Re-install the nylon split tubing around the main wire loom. Use electrical tape to secure the flexible tubing.

45. Connect the detonation sensor and crankshaft position sensor connectors before installing the supercharger.

Supercharger Installation:

46. When installing the supercharger, the supercharger drive pulley and snout slides under the power steering pump return hose. See (Figure 24). Before sliding the supercharger manifold over the attachment studs, insert the fuel line banjo fitting through the manifold between intake ports three and four. It is easiest to do this as the manifold is being lowered into place after the supercharger snout is in position. Use another person if necessary to help with the fuel inlet banjo fitting. Snug all the nuts and bolts to secure the supercharger to the cylinder head. Start in the center of the manifold and work outward towards the ends. Torque fasteners to 22 ft-lbs.

47. Rotate the supercharger nose support bracket to align the slot in the bracket with the idler bracket bolt hole. See (Figure 24). Use the supplied 10mm x 1.25 x 25mm long hex bolt and 10mm washer to secure the nose support bracket to the idler bracket. Finger tighten bolt.

48. Using the 8mm flange head nut supplied, secure the upper portion of the manifold support to the 8mm stud that is in the bottom-side of the intake manifold. The stud should protrude through the slot in the manifold support bracket. See Figure 25. Tighten bracket to supercharger first, and then also tighten to the engine mount. Torque: 15 ft-lbs. Finally, torque the manifold bracket 8mm through bolt and nylock nut to15 ft-lbs.

49. Tighten the 10mm bolt that secures the nose support bracket to the idler pulley bracket. Torque to 30 ft-lbs.

50. Tighten the socket head cap screw to secure the nose support bracket to the supercharger nose. Torque to 10 ft-lbs.

51. Check both the power steering pressure hose and return hose for clearance to the supercharger snout. Both lines should not touch the supercharger. Adjust lines as necessary.

52. Reconnect the fuel inlet banjo fitting to fuel rail. Torque to 22 ft-lbs.

53. Reconnect all four fuel injection connectors.

54. Attach injector wiring ground strap removed in Step 23 to the supercharger intake manifold using the supplied 6mm hex bolt and washer. Clean wires and and the connection location before installing. See (Figure 26). Torque to 6 ft-lbs NOTE: If your vehicle has eight round intake manifold ports, then skip to step 64. If your vehicle has four oval ports, then follow steps 62 and 63.

55. Route the crankshaft position sensor connector down through the opening between the intake port one and intake port two of the supercharger manifold and connect to the crankshaft position sensor.

56. Route detonation sensor connector through the intake manifold between ports two and three, and then connect to the detonation sensor.

57. Reconnect power steering idle up connector. Install the OE wiring bracket on to the super charger stud. Torque nylock nut to 15 ft-lbs. See (Figure 27).

58. On vehicles with EGR, remove the EGR temperature sensor (Arrow A) and EGR modulator bracket (Arrow B) from the OE intake chamber. See (Figure 28).

59. Check the OE intake chamber that was removed from the vehicle. Look at the quantity and location of the PCV breather fitting that are next to the throttle body surface. See (Figure 29).

60. Check the intake chamber to make sure that the quantity and location of the PCV / breather fittings match the OE intake chamber. See (Figure 30). NOTE: The intake chamber is photographed off the engine for clarity. If the fittings match, then proceed with Step 68. If the fittings do not match, then use the supplied fittings to duplicate the previous /breather fittings in the OE intake chamber. Re-use the 16mm nylon washers to seal the fittings into the intake chamber.

61. If vehicle has EGR, install the EGR temperature sensor (Arrow A) to the intake chamber. See (Figure 30). Otherwise, install the supplied 10mm x 1.25 x 12mm long bolt. Teflon thread tape is recommended.

62. If vehicle has EGR then proceed with Steps 62 through 75, If vehicle has no EGR, then skip to Step 68.

63. Use one of the supplied EGR gaskets and install the EGR valve to the backside of the intake chamber. See (Figure 31). Use the OE EGR valve nuts removed in Step 14. Leave the nuts loose at this time.

64. Use the second supplied EGR gasket and connect the EGR feed tube to the EGR valve. Again, use the OE nuts removed in Step 13. Leave nuts loose at this time.

65. Torque EGR valve nuts to 14 ft-lbs.

66. Install EGR feed tube. Torque to 14 ft-lbs

67. Reconnect EGR coolant hose removed in Step 31.

68. Re-install the EGR modulator bracket to the backside of the intake manifold using the OE bolt removed in Step 65. Refer to (Figure 31)

69. If the vehicle has no EGR, then use one EGR gasket, block-off plate, and two 8 x 1.25mm flange nuts to seal the EGR passage located on the backside of the intake chamber. See (Figure 32). Torque nuts to 14 ft-lbs

70. Position supplied throttle body gasket on to the studs on the intake chamber. Position the OE throttle body also on the studs.

71. Reconnect TPS and lAC connectors to the sensors in the throttle body also reinstall coolant lines.

72. Reconnect cam position sensor connector removed in Step 27.

73. Tighten the OE nuts and bolts to secure the throttle body to the intake chamber. Torque to 14 ft-lbs

74. Reconnect the brake booster vacuum hose to the hose fitting on the side of the intake chamber. Cut hose if needed. See (Figure 33) Arrow "A"

75. Remove the OE fuel return pipe and hose. Disconnect the OE hose at the hard line that is mounted on the inner fender panel. Install the new supplied fuel return hose using the OE clamps removed in Step 24. Route the new hose under the supercharger. Hook up new line at the frame rail.

76. HIGH BOOST ONLY! Remove the OE fuel return pipe and hose. Disconnect the OE hose at the hard line that is mounted on the inner fender panel. Install the new supplied fuel return hose using the OE clamps removed in Step 24. Route the new hose under the supercharger. Hook up new line at the frame rail.