Toyota Trucks and SUV Cold Air Intake 4.0L V6 PDF Installation Manual

A. Check Kit Contents
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.
3. Apply vehicle protection to prevent damage to painted surfaces.
4. Remove negative battery cable from terminal.
5. Prior to installation, make sure all parts of the Cold Air Intake are clean and free of debris.
i. 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. Use a 10mm socket and ratchet assembly to remove (2) 10mm nuts.
ii. Lift front of cover off studs and pull forward to disengage rear mounts.
2. Disconnect breather hose from factory air filter assembly. (Fig. C2)
3. Disconnect the vacuum hose from rear of air box. (Fig. C3)
4. Loosen the two factory hose clamps with a 10mm socket and ratchet assembly. (Fig. C4)
5. Remove the two 12mm bolts. (Fig. C4)
6. Disconnect MAF sensor connector. (Fig. C5)
i. Push clip to release connector.
7. Remove the MAF sensor from the air filter lid by unscrewing the (2) Phillips head screws. (Fig. C5)
i. Do not touch the internal sensor surfaces.
ii. Protect the sensor from damage.
8. Disengage the two wire harness clamps from air box. (Fig. C6)
9. Disconnect the air filter inlet hose and remove the air filter housing assembly.
10. Remove intake air tube from inner fender
i. Remove two 12mm bolts. (Fig. C7)
11. Remove the factory rubber grommets and steel sleeves from the air filter assembly as shown. (Fig. C8)

D. Install TRD Air Intake
1. Grasp the supplied trim seal and press firmly onto the TRD air filter housing inlet. (Fig. D1)
i. Use entire length of trim seal to surround air filter housing inlet.
2. Insert rubber grommets and sleeves removed in Step C11 into TRD air filter housing as shown. (Fig. D2)
i. Insert rubber grommets first, then push sleeves into place.
3. Remove 12mm bolt that secures the factory AC line mounting bracket. (Fig. D3)
4. Install the supplied 8mm rubber mount into the threaded hole left open from the previous step.
i. Hand-tighten rubber mount. (Fig. D4)
5. Install TRD air filter housing.
i. Align TRD housing so factory rubber grommets are directly over the mounting holes in the inner fender well, and the top 8mm thread side of the rubber mount protrudes through TRD housing. (Fig. D5)
ii. Install the 12mm bolts removed in Step. C5 through the rubber grommets in the housing. (Fig. D6)
iii. Install the supplied 8mm flat washer and 8mm nut onto the 8mm threads of the rubber mount as shown. (Fig. D6)
iv. Tighten bolts to 60 in. lbf. + 5 in. lbf. (6.7 Nm + 0.6 Nm).
v. Tighten nut to 60 in. lbf. + 5 in. lbf. (6.7 Nm + 0.6 Nm).
6. Install the air filter adapter. (Fig. D7)
i. Insert hose end side of air filter adapter through the air filter housing from the inside as shown. (Fig. D7)
ii. Use a 4mm Allen Wrench and 3 supplied Button-Head screws to secure adapter to housing. (Fig. D7)
iii. Torque screws to 20 in. lbf. + 3 in. lbf. (2.3 Nm + 0.3 Nm (Fig. D7)
7. Use a 4mm 12-point socket to remove the stud in the factory air filter housing as shown. (Fig. D8)
8. Install the stud removed in the previous step into the threaded insert in the TRD intake tube. (Fig. D9)
i. Torque stud to 35 in. lbf. + 5 in. lbf (4.0 Nm + 0.5 Nm
9. Install supplied hose barb fitting into TRD intake tube as shown. (Fig. D10)
i. Apply teflon pipe sealant or teflon tape to hose barb fitting threads.
ii. Use a 7/16” wrench to install hose barb fitting. (Fig. D10)
Caution: Do not over-tighten fitting. Maximum torque is 60 in. lbf.