TOYOTA TACOMA / FJ PERFORMANCE AIR

Section I – Installation Preparation 2005 - INTAKE 4.0L V6 (1GR-FE)

Part Number(s): PTR03-35090
Kit Contents Additional Items Required For Installation
Item # Quantity Reqd. Description Item # Quantity Reqd. Description
1 1 Air Filter (PTR43-00083) 1 1 Blue Thread Locking Fluid
2 1 Upper Air Box General Applicability
3 1 Lower Air Box Tacoma w/1GR-FE V6 engine: 2005 → 2011
4 1 Hump Coupler
FJ Cruiser w/1GR-FE V6 engine: 2007 → 2009
5 1 Throttle Body Coupler
6 1 Air Inlet Tube
7 1 Air Flow Accelerator Conflicts
Hardware Bag Contents Note: TRD 4.0L 1GR-FE V-6 Supercharger
Item # Quantity Reqd. Description Recommended Sequence of Installation
1 2 #52 Hose Clamp If any other accessories are to be installed, it is recommended
2 2 #72 Hose Clamp they be installed in the order described below to ease
3 1 Plastic Nipple, 1/8” installation and/or avoid redundant work.
4 1 Bolt, M8 X 1.25 X 30mm Item # Accessory
5 1 Hose, 5/32” ID X 20”
6 1 Washer, M8
7 2 Air Box Clip *Mandatory
8 1 Filter Minder Grommet Legend
9 1 Filter Minder
STOP: Damage to the vehicle may occur. Do not
10 1 Nylon Tie Strap, Tree Mount proceed until process has been complied with.
11 2 Nylon Tie Strap, 6”
OPERATOR SAFETY: Use caution to avoid risk of
12 1 Plastic Nipple, 5/8” X 90deg. injury.
13 1 Bracket, Wire Harness CAUTION: A process that must be carefully observed
14 1 Bolt, M6 X 1.0 X 12mm in order to reduce the risk of damage to the
15 1 Plug, Plastic Tree Clip accessory/vehicle and to ensure a quality installation.
16 2 Bolt, Socket M4 X 0.7 X 8mm TOOLS & EQUIPMENT: Used in Figures calls out the
specific tools and equipment recommended for this
Literature Bag Contents process.
Item # Quantity Reqd. Description REVISION MARK: This mark highlights a change in
1 1 Instructions installation with respect to previous issue.

SAFETY TORQUE: This mark indicates that torque is

Recommended Tools related to safety.
Safety Tools
Vehicle Protection Blankets or Fender Covers
Special Tools Please see page 14 for important “Care and
None Required Maintenance” information!
Installation Tools
Nut driver 8mm or 5/16” Torque Specifications:
10mm socket ¼” drive i. M8 Hardware: Tighten to 60 in. lbf. + 5
12mm socket ¼” drive in. lbf. (6.7 Nm + 0.6 Nm).
13mm socket ¼” drive
¼” drive ratchet ii. M6 Hardware: Tighten to 40 in. lbf. + 5
¼” drive extension 6” long
in. lbf. (4.5 Nm + 0.6 Nm)
Phillips head screwdriver #2
Screwdriver, std. #2 iii. M4 Hardware: Tighten to 10 in. lbf. + 2
Allen wrench 3mm
Socket, External Torx E6 in. lbf. (1.1 Nm + 0.2 Nm)
Torque wrench in. lbf. (0 – 120 in. lbf.)
Special Chemicals iv. Hose Clamp: Tighten to 30 in. lbf. + 5
Glass cleaner in. lbf. (3.4Nm + 0.6 Nm)

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 TOYOTA TACOMA / FJ PERFORMANCE AIR
Section II – Installation 2005 - INTAKE 4.0L V6 (1GR-FE)

Emissions Compliance Information:

A new process has been implemented. No longer is

the Emissions Label included in the Performance Air
Intake Kit.

If your state requires an Emissions Compliance

Label, one may be ordered through your Toyota
dealer or the Toyota Materials Distribution Center
(MDC) 310-468-9800 or MDC@toyota.com

This TRD Performance Air Intake Kit has received

50-State Emissions Compliance via the California Air
Resources Board (CARB). Not all states require the
Emissions Compliance Label but TRD does
recommend ordering one. To receive the proper
Emissions Compliance Label for this TRD
Performance Air Intake Kit, please order MDC part
number 00602-35120. Proof of ownership may be
required.

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.
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. Blow out the inside of the tube and air

box with compressed air.
Fig. C1

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TOYOTA TACOMA / FJ PERFORMANCE AIR
Section II – Installation 2005 - INTAKE 4.0L V6 (1GR-FE)
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) M6 nuts.
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)

4. Loosen the two factory hose clamps with a Remove hose

10mm socket and ratchet assembly. (Fig. C4)
Fig. C3
5. Remove the two M6 bolts. (Fig. C4)

Remove
10mm bolt

Loosen 10mm
hose clamps

6. Disconnect MAF sensor connector. (Fig. C5)

i. Push clip to release connector.
Remove
7. Remove the MAF sensor from the air filter lid 10mm bolt

by unscrewing the (2) Phillips head screws. Fig. C4

Set the MAF sensor aside. (Fig. C5)

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 TOYOTA TACOMA / FJ PERFORMANCE AIR
Section II – Installation 2005 - INTAKE 4.0L V6 (1GR-FE)
STOP
i. Do not touch the internal sensor
surfaces.

STOP ii. Protect the sensor from damage.

Push clip to Remove two

release connector screws

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. Fig. C5

Disengage two
clamps

10. Remove intake air tube from inner fender

Fig. C6
i. Remove two M8 bolts. (Fig. C7)
ii. 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.

Fig. C7

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TOYOTA TACOMA / FJ PERFORMANCE AIR
Section II – Installation 2005 - INTAKE 4.0L V6 (1GR-FE)

Remove one rubber

grommet and sleeve
11. Remove one of the factory rubber grommets
and steel sleeve from the air filter assembly as
shown. (Fig. C8)

Fig. C8

12. Remove two of the factory rubber grommets

and steel sleeves from the air tube as shown.
(Fig. C9)

Remove two rubber

Fig. C9 grommets and sleeves

Insert taller
rubber grommet
and sleeve here

D. Install TRD Air Intake

1. Insert the taller rubber grommet and sleeve

removed in step C11 into the TRD lower air
box in the location shown. (Fig. D1)

i. Insert rubber grommet first, then push

sleeve into place. Fig. D1

Insert rubber
grommets and
sleeves here

2. Insert rubber grommets and sleeves removed

in Step C12 into TRD air filter housing as
shown. (Fig. D2)

i. Insert rubber grommets first, then push

Fig. D2
sleeves into place.
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TOYOTA TACOMA / FJ PERFORMANCE AIR
Section II – Installation 2005 - INTAKE 4.0L V6 (1GR-FE)

3. Install air box clips by clipping them onto the

mounts as shown. (Fig. D3)
Install air box
i. If necessary, use pliers to gently clips here

tighten the closed end of the clip so that it

clips onto the mount securely.
Fig. D3

4. Remove M8 bolt that secures the factory AC

line mounting bracket. (Fig. D4)

Fig. D4

5. Install the TRD intake flow accelerator by

squeezing it through the hole in the inner
fender as shown. (Fig. D5)

i. The TRD logo should face up. (Fig.

D6) Fig. D5

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TOYOTA TACOMA / FJ PERFORMANCE AIR
Section II – Installation 2005 - INTAKE 4.0L V6 (1GR-FE)

TRD
Logo

Fig. D6

6. Install TRD lower air box.

Loosen M6 nut to
adjust clearance
i. Insert the neck of the lower air box with the A/C line
into the intake flow accelerator installed in
step D5. Make sure that the intake flow
Install supplied M8
accelerator is rotated such that the cut outs bolt and washer
engage the barbs on the neck.
ii. Align TRD lower air box so that
factory rubber grommets are directly over
the mounting holes in the inner fender
well. (Fig. D7)
iii. Secure the lower air box using the two
M8 bolts removed in step C10, and the
supplied M8 bolt and washer. (Fig. D7) If Install M8 bolts
Fig. D7 removed in step C10
necessary, use an M8 X 1.25 tap to clean
paint / undercoat from the threaded holes.
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)

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TOYOTA TACOMA / FJ PERFORMANCE AIR
Section II – Installation 2005 - INTAKE 4.0L V6 (1GR-FE)
7. Install TRD panel filter and wire harness Supplied
bracket. (Fig. D8) bracket and
M6 bolt
i. Make sure that the filter sits all the
way down in the lower air box.
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.
Fig. D8

8. 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)

Insert filter
minder grommet
Fig. D9

9. Insert the filter minder into the grommet

installed in step D8.
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.
D10)

Fig. D10

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TOYOTA TACOMA / FJ PERFORMANCE AIR
Section II – Installation 2005 - INTAKE 4.0L V6 (1GR-FE)
10. Install the hump hose coupler onto the upper
air box using the two #72 hose clamps.
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)

Fig. D11

11. Install the upper air box by lowering the hinge 1

side into place first. (Fig. D12)
i. Make sure that the hinge pieces on the
upper air box fully engage with the
2
corresponding pieces on the lower air box.
ii. To achieve propper fit, the upper air
box needs to be aligned correctly, then slid 3
toward the drivers side of the vehicle
before rotating the upper air box down Fig. D12
into place.

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

Secure wiring
Fig. D13 with tie strap

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TOYOTA TACOMA / FJ PERFORMANCE AIR
Section II – Installation 2005 - INTAKE 4.0L V6 (1GR-FE)

13. Use an E6 Torx socket to remove the stud in

the factory air filter housing as shown. (Fig.
D14)

14. Install the factory MAF sensor into the TRD Fig. D14
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. Supplied M4 screws
(Fig. D15)
i. Use a small amount of blue thread locking
fluid on the M4 screws to prevent them
from working loose.

15. Assemble the throttle body coupler and plastic

nipples. (Fig. D18)
Fig. D15 Install stud here
i. Install the plastic nipples by firmly
pressing them into place as shown. A
small amount of silicone spray, or similar
lubricant may aid installation
ii. Slide the throttle body coupler onto the
end of the TRD inlet pipe with the two
#52 hose clamps.
iii. With the hose clamps loose slide the
coupler all the way onto the pipe as far as Plastic Nipples
it will go.
16. Install the inlet pipe assembly by inserting the
Fig. D18
big end of the pipe into the hump coupler first,
then lower the small end into position. (Fig.
D19)
i. Leave the hose clamps loose for now.

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TOYOTA TACOMA / FJ PERFORMANCE AIR
Section II – Installation 2005 - INTAKE 4.0L V6 (1GR-FE)

17. Slide the throttle body coupler over the

throttle body until it reaches the stops.
i. On N/A applications, the pipe end of
the coupler should approximately line up
with the middle bead on the pipe. (Fig.
D20)

Fig. D19

Fig. D20

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TOYOTA TACOMA / FJ PERFORMANCE AIR
Section II – Installation 2005 - INTAKE 4.0L V6 (1GR-FE)

18. Connect the factory crank case vent and Connect

vacuum hose
vacuum hose. (Fig. D21) Secure vacuum
hose with nylon
i. Replace the factory vacuum hose with tie strap
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.
Connect
Fig. D21 crankcase vent

19. Install engine cover onto rear rubber mounts

and rotate the cover down onto the front studs.
i. Adjust the positioning of the TRD
inlet tube until the mounting studs line up
with the holes in the engine cover. (Fig.
D22)
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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TOYOTA TACOMA / FJ PERFORMANCE AIR
Section II – Installation 2005 - INTAKE 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)

22. Re-install negative battery cable to negative

terminal. Tighten nut to 36 in. lbf. + 4 in. lbf. Fig. D24
(4.0 Nm + 0.4 Nm)

23. Installer – The installation manual contains

important “Care and Maintenance”
information. Place the entire instruction
manual in the glove box for owner’s future
reference.

Emissions Compliance Information:

A new process has been implemented. No longer is

the Emissions Label included in the Performance Air
Intake Kit.

If your state requires an Emissions Compliance

Label, one may be ordered through your Toyota
dealer or the Toyota Materials Distribution Center
(MDC) 310-468-9800 or MDC@toyota.com

This TRD Performance Air Intake Kit has received

50-State Emissions Compliance via the California Air
Resources Board (CARB). Not all states require the
Emissions Compliance Label but TRD does
recommend ordering one. To receive the proper
Emissions Compliance Label for this TRD
Performance Air Intake Kit, please order MDC part
number 00602-35120. Proof of ownership may be
required.

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TOYOTA TACOMA / FJ PERFORMANCE AIR
Section III – Care and Maintenance 2005- INTAKE 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 high-
performance 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 high-
performance 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 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.

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TOYOTA TACOMA / FJ PERFORMANCE AIR
Section IV – Trouble Shooting 2005- INTAKE 4.0L V6 (1GR-FE)
Check: Look For:

Start the vehicle.

o Full engagement of MAF sensor connector.
If after you start the vehicle, or while
o Tightness of all clamps.
driving, you encounter a Malfunction
Indictor Lamp (MIL), check the following: o Correctly installed valve cover breather
hose.
o Over-oiled air filter.

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 o Contact your Toyota dealer as soon as
checking and/or repairing any of the above: possible.

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