Cold Air Intake
TOYOTA TRUCKS / SUVs
2003 -
COLD AIR INTAKE
4.0L V6 (1GR-FE)
Section I – Installation Preparation
Additional Items Required For Installation
Part Number(s): PTR03-35090
Item #
1
Kit Contents
Item #
1
2
3
4
5
6
7
Quantity Reqd.
1
1
1
1
1
1
1
Description
Air Filter
Upper Air Box
Lower Air Box
Hump Coupler
Throttle Body Coupler
Air Inlet Tube
Air Flow Accelerator
Quantity Reqd.
2
2
1
1
1
1
2
1
1
1
2
1
1
1
1
2
General Applicability
Conflicts
Note: None
Recommended Sequence of Installation
Description
#52 Hose Clamp
#72 Hose Clamp
Plastic Nipple, 1/8”
Bolt, M8 X 1.25 X 30mm
Hose, 5/32” ID X 20”
Washer, M8
Air Box Clip
Filter Minder Grommet
Filter Minder
Nylon Tie Strap, Tree Mount
Nylon Tie Strap, 6”
Plastic Nipple, 5/8” X 90deg.
Bracket, Wire Harness
Bolt, M6 X 1.0 X 12mm
Plug, Plastic Tree Clip
Bolt, Socket M4 X 0.7 X 8mm
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
STOP
Literature Bag Contents
Item #
1
2
Quantity Reqd.
1
1
Description
Instructions
C.A.R.B E.O. Decal
Torque Specifications:
Blankets or Fender Covers
Special Tools
None Required
Installation Tools
Nut driver
10mm socket
12mm socket
13mm socket
¼” drive ratchet
¼” drive extension
Phillips head screwdriver
Screwdriver, std.
Allen wrench
Socket, External Torx E6
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 13 for important “Care and
Maintenance” information!
Recommended Tools
Safety Tools
Vehicle Protection
Description
Blue Thread Locking Fluid
Tacoma w/1GR-FE V6 engine: 2005 →
FJ Cruiser: 2007 → 2009
4Runner w/1GR-FE V6 engine: 2003 - 2009
Hardware Bag Contents
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Quantity Reqd.
1
M8 Hardware: Tighten to 60 in. lbf. + 5
in. lbf. (6.7 Nm + 0.6 Nm).
i.
M6 Hardware: Tighten to 40 in. lbf. + 5
in. lbf. (4.5 Nm + 0.6 Nm)
ii.
8mm or 5/16”
¼” drive
¼” drive
¼” drive
M4 Hardware: Tighten to 10 in. lbf. + 2
in. lbf. (1.1 Nm + 0.2 Nm)
iii.
6” long
#2
#2
3mm
Hose Clamp: Tighten to 30 in. lbf. + 5
in. lbf. (3.4Nm + 0.6 Nm)
iv.
in. lbf. (0 – 120 in. lbf.)
Special Chemicals
Glass cleaner
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12/14/09
Page 1 of 16 pages
DIO
TOYOTA TRUCKS / SUVs
2003 COLD AIR INTAKE
Section II – Installation
4.0L V6 (1GR-FE)
A. Check Kit Contents
Check kit for contents and damage.
1.
B. Vehicle and Parts Preparation
1.
Completely read instructions and familiarize
yourself with the installation before beginning.
2.
Open hood.
3.
Apply vehicle protection to prevent damage to
painted surfaces.
STOP
Remove negative battery cable from terminal.
STOP
4.
5.
Prior to installation, make sure all parts of the
Cold Air Intake are clean and free of debris.
STOP
i.
Blow out the inside of the tube and air
box with compressed air.
Fig. C1
C. Remove Factory Components
Operations Performed in the Engine Compartment
1.
Remove engine cover. (Fig. C1)
Use a 10mm socket and ratchet
assembly to remove (2) M6 nuts.
i.
ii.
Lift front of cover off studs and pull
forward to disengage rear mounts.
Fig. C2
2.
Disconnect breather hose from factory air
filter assembly. (Fig. C2)
3.
Disconnect the vacuum hose from rear of air
box. (Fig. C3)
Remove hose
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DIO
Fig. C3
TOYOTA TRUCKS / SUVs
2003 COLD AIR INTAKE
Section II – Installation
4.0L V6 (1GR-FE)
4.
Loosen the two factory hose clamps with a
10mm socket and ratchet assembly. (Fig. C4)
Remove
10mm bolt
Remove the two M6 bolts. (Fig. C4)
5.
Loosen 10mm
hose clamps
Remove
10mm bolt
Fig. C4
6.
Disconnect MAF sensor connector. (Fig. C5)
i.
Push clip to release connector.
Remove the MAF sensor from the air filter lid
by unscrewing the (2) Phillips head screws. Set the
MAF sensor aside. (Fig. C5)
7.
i.
surfaces.
Do not touch the internal sensor
ii.
Protect the sensor from damage.
STOP
STOP
Push clip to
release connector
Fig. C5
Disengage the two wire harness clamps from
air box. (Fig. C6)
8.
Disengage two
clamps
Disconnect the air filter inlet hose and remove
the air filter housing assembly.
9.
Fig. C6
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DIO
Remove two
screws
TOYOTA TRUCKS / SUVs
2003 COLD AIR INTAKE
Section II – Installation
4.0L V6 (1GR-FE)
10.
Remove intake air tube from inner fender
i.
Remove two M8 bolts. (Fig. C7)
On FJ Cruiser Model, remove the
additional piece of the stock inlet air tube
that is attached to the outside of the engine
compartment.
iii.
Lower the inner fender liner by
removing the 5 screws.
iv.
Remove the plastic air duct by
removing the two M8 bolts securing it to
the outside of the apron.
v.
Re-install the inner fender liner before
proceeding.
ii.
Fig. C7
Remove one of the factory rubber grommets
and steel sleeve from the air filter assembly as shown.
(Fig. C8)
11.
Remove one rubber
grommet and sleeve
Fig. C8
12.
Remove two of the factory rubber grommets
and steel sleeves from the air tube as shown. (Fig. C9)
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DIO
Fig. C9
Remove two rubber
grommets and sleeves
TOYOTA TRUCKS / SUVs
2003 COLD AIR INTAKE
Section II – Installation
4.0L V6 (1GR-FE)
Issue A:
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DIO
TOYOTA TRUCKS / SUVs
2003 COLD AIR INTAKE
Section II – Installation
4.0L V6 (1GR-FE)
Insert taller
rubber grommet
and sleeve here
D. Install TRD Air Intake
Insert the taller rubber grommet and sleeve
removed in step C11 into the TRD lower air box in
the location shown. (Fig. D1)
1.
Insert rubber grommet first, then push
sleeve into place.
i.
Fig. D1
Insert rubber
grommets and
sleeves here
Insert rubber grommets and sleeves removed
in Step C12 into TRD air filter housing as shown.
(Fig. D2)
2.
Insert rubber grommets first, then push
sleeves into place.
i.
Fig. D2
3.
Install air box clips by clipping them onto the
mounts as shown. (Fig. D3)
i.
If necessary, use pliers to gently
tighten the closed end of the clip so that it clips onto
the mount securely.
Install air box
clips here
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DIO
Fig. D3
TOYOTA TRUCKS / SUVs
2003 COLD AIR INTAKE
Section II – Installation
4.0L V6 (1GR-FE)
Remove M8 bolt that secures the factory AC
line mounting bracket. (Fig. D4)
4.
Fig. D4
Install the TRD intake flow accelerator by
squeezing it through the hole in the inner fender as
shown. (Fig. D5)
5.
i.
D6)
The TRD logo should face up. (Fig.
Fig. D5
TRD
Logo
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DIO
Fig. D6
TOYOTA TRUCKS / SUVs
2003 COLD AIR INTAKE
Section II – Installation
4.0L V6 (1GR-FE)
Install TRD lower air box.
6.
Insert the neck of the lower air box
into the intake flow accelerator installed in step D5.
Make sure that the intake flow accelerator is rotated
such that the cut outs engage the barbs on the neck.
Loosen M6 nut to
adjust clearance
with the A/C line
i.
Install supplied M8
bolt and washer
ii.
Align TRD lower air box so that
factory rubber grommets are directly over the
mounting holes in the inner fender well. (Fig. D7)
Secure the lower air box using the two
M8 bolts removed in step C10, and the supplied M8
bolt and washer. (Fig. D7) If necessary, use an M8 X
1.25 tap to clean paint / undercoat from the threaded
holes.
iii.
iv.
If additional clearance is needed
between the A/C line and the lower air box, loosen
the M6 nut on the clamp, and slide the A/C line away
from the air box until there is sufficient clearance.
(Inset – Fig. D7)
Fig. D7
Supplied
bracket and
M6 bolt
7.
Install TRD panel filter and wire harness
bracket. (Fig. D8)
Make sure that the filter sits all the
way down in the lower air box.
i.
ii.
Install the supplied wire harness
bracket and M6 bolt on the head cover where
indicated in Fig. D8. Clip the factory wire harness
into the oblong hole on the bracket.
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Install M8 bolts
removed in step C10
Fig. D8
TOYOTA TRUCKS / SUVs
2003 COLD AIR INTAKE
Section II – Installation
4.0L V6 (1GR-FE)
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. D9)
8.
Fig. D9
9.
Insert the filter minder into the grommet
installed in step D8.
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. D10)
i.
Fig. D10
Install the hump hose coupler onto the upper
air box using the two #72 hose clamps.
10.
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. D11
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DIO
Insert filter
minder grommet
TOYOTA TRUCKS / SUVs
2003 COLD AIR INTAKE
Section II – Installation
4.0L V6 (1GR-FE)
Install the upper air box by lowering the hinge
side into place first. (Fig. D12)
11.
1
i.
Make sure that the hinge pieces on the
upper air box fully engage with the corresponding
pieces on the lower air box.
2
ii.
To achieve propper fit, the upper air
box needs to be aligned correctly, then slid toward the
drivers side of the vehicle before rotating the upper
air box down into place.
3
Fig. D12
12.
Secure the upper air box with the two clips
installed in step D3. (Fig. D13)
i.
Secure the wiring to the hole in the
airbox using the supplied tree-mount tie strap.
Secure with
two clips
Fig. D13
Use an E6 Torx socket to remove the stud in
the factory air filter housing as shown. (Fig. D14)
13.
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DIO
Fig. D14
Secure wiring
with tie strap
TOYOTA TRUCKS / SUVs
2003 COLD AIR INTAKE
Section II – Installation
4.0L V6 (1GR-FE)
Supplied M4 screws
Install the factory MAF sensor into the TRD
intake pipe using a 3mm allen wrench and the
supplied M4 screws. Also install the M6 stud
removed in step D13 using the E6 socket. (Fig. D15)
14.
i.
Use a small amount of blue thread locking
fluid on the M4 screws to prevent them from working
loose.
Fig. D15
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DIO
Install stud here
TOYOTA TRUCKS / SUVs
2003 COLD AIR INTAKE
Section II – Installation
4.0L V6 (1GR-FE)
Assemble the throttle body coupler and plastic
nipples. (Fig. D18)
15.
Install the plastic nipples by firmly
pressing them into place as shown. A small amount of
silicone spray, or similar lubricant may aid
installation
i.
Slide the throttle body coupler onto the
end of the TRD inlet pipe with the two #52 hose
clamps.
ii.
With the hose clamps loose slide the
coupler all the way onto the pipe as far as it will go.
iii.
Plastic Nipples
Fig. D18
Install the inlet pipe assembly by inserting the
big end of the pipe into the hump coupler first, then
lower the small end into position. (Fig. D19)
16.
Leave the hose clamps loose for now.
i.
Fig. D19
17.
Slide the throttle body coupler over the
throttle body until it reaches the stops.
On N/A applications, the pipe end of
the coupler should approximately line up with the
middle bead on the pipe. (Fig. D20)
i.
ii.
On Super Charged applications, the
pipe end of the coupler should approximately line up
with the inner bead on the pipe.
Fig. D20
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TOYOTA TRUCKS / SUVs
2003 COLD AIR INTAKE
Section II – Installation
4.0L V6 (1GR-FE)
18.
Connect the factory crank case vent and
vacuum hose. (Fig. D21)
Replace the factory vacuum hose with
the longer one supplied in the kit. Connect it between
the fuel pressure regulator and the small plastic nipple
on the throttle body coupler. Secure the hose to the
wire harness where indicated using the supplied nylon
tie strap.
i.
Connect
vacuum hose
Secure vacuum
hose with nylon
tie strap
Fig. D21
Install engine cover onto rear rubber mounts
and rotate the cover down onto the front studs.
19.
Adjust the positioning of the TRD inlet
tube until the mounting studs line up with the holes in
the engine cover. (Fig. D22)
i.
ii.
Remove the engine cover and tighten
all hose clamps.
Fig. D22
20.
Plug in the MAF sensor and do a final check
that all hose clamps and hardware are secure. (Fig.
D23)
Fig. D23
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DIO
Connect
crankcase vent
TOYOTA TRUCKS / SUVs
2003 COLD AIR INTAKE
Section II – Installation
4.0L V6 (1GR-FE)
21.
Reinstall the engine cover and secure it with
the original M6 nuts that were removed in step C1.
(Fig. D24)
Tighten nuts to 40 in. lbf. + 4 in. lbf. (4.5 Nm
+ 0.45 Nm)
Re-install negative battery cable to negative
terminal. Tighten nut to 36 in. lbf. + 4 in. lbf. (4.0 Nm
+ 0.4 Nm)
22.
Installer – The installation manual contains
important “Care and Maintenance” information.
Place the entire instruction manual in the glove box
for owner’s future reference.
23.
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Fig. D24
TOYOTA TRUCKS / SUVs
2003 COLD AIR INTAKE
Section III – Care and Maintenance
4.0L V6 (1GR-FE)
Section III – Care and Maintenance
Air Filter Maintenance
Service Intervals- Service your TRD filter
element with TRD's filter cleaning kit (Toyota p/n
PTR43-00088). We recommend that TRD filter
elements be serviced every 30,000 miles (or
sooner if needed) on off-road and highperformance street applications.
If you live in a region with extremely fine dust
(arid or desert climates for example), follow the
recommended schedule for off-road and highperformance vehicles.
Always inspect your filter element whenever you
change your oil.
Do not over-oil the filter. This could contaminate
the MAF sensor and cause the MIL (Malfunction
Indicator Lamp) to illuminate and require nonwarrantable 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.
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TOYOTA TRUCKS / SUVs
2003 -
COLD AIR INTAKE
4.0L V6 (1GR-FE)
Section IV – Trouble Shooting
Check:
Look For:
Start the vehicle.
If after you start the vehicle, or while
driving, you encounter a Malfunction
Indictor Lamp (MIL), check the following:
o
Full engagement of MAF sensor connector.
o
Tightness of all clamps.
o
Correctly installed valve cover breather
hose.
Over-oiled air filter.
o
Over-oiled Air Filter:
o
Clean the air filter as indicated in the TRD
Filter Cleaning Kit and apply the proper
amount of oil.
o
Replacement (non-warrantable) of the MAF
sensor may be required.
Start the vehicle
If the lamp will not go off even after
checking and/or repairing any of the above:
o Contact your Toyota dealer as soon as
possible.
Issue A:
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DIO
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