Vortech 2003-2005 Lexus 3.0L IS300 User Manual

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DP/N: 4LA020-010 - v1.1 07/10/07

1650 Pacific Avenue, Channel Islands CA 93033-9901 • Phone: 805 247-0226

Fax: 805 247-0669 • www.vortechsuperchargers.com • M-F 8:00AM - 4:30PM (PST)

ENGINEERING, LLC

Lexus

3.0L IS300

Supercharger System

Installation Instructions

2001-2005 Model Year

*Legal in California only for racing vehicles which may never be used upon a highway.

FOREWORD

All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, or translated into another language in any form, by any means without written permission of Vortech Engineering, LLC.

Take note of the following before proceeding:

1. Proper installation of this supercharger kit requires general automotive mechanic knowledge and experience. Please browse through each step of this instruction manual prior to beginning the installatlion to determine if you should refer the job to a professional installer/technician. Please contact

your dealer or Vortech Engineering for possible installers in your area.

2. This product was designed for use on stock (un-modified, OEM) vehicles. The

PCM (computer), engine, transmission, drive axle ratios and tire O.D. must be stock. If the vehicle or engine has been modified in any way, check with Vortech prior to installation and use of this product.

3. Use only premium grade fuel with a minimum of 91 octane (R+M/2).

4. Always listen for any sign of detonation (knocking/pinging) and discontinue hard use (no

boost) until the problem is resolved.

5. Vo r tech is not responsible for any clutch, transmission, drive-line or engine damage.

Exclusions from Vortech warranty coverage considerations include, but not limited to:

1. Neglect, abuse, lack of maintenance, abnormal operation or improper installation.

2. Continued operation with an impaired vehicle or sub-system.

3. The combined use of Vortech components with other modifications such as, but not limit-

ed to, exhaust headers, aftermarket camshafts, nitrous oxide, third party PCM programming or other such changes.

his manual provides information on the installation, maintenance and service of the Vor tech supercharger kit expressly designed for this vehicle. All information, illustra-

tions and specifications contained herein are based on the latest product information available at the time of this publication. Changes to the manual may be made at any time without notice. Contact Vortech Engineering for any additional information regarding this kit and any of these modifications at (805) 247-0228 8:00am-4:30pm PST.

NOTICE

Due to variances in each vehicle, Vortech recommends that the vehicle get a “custom tune” from a local, reputable tuner.

This kit is supplied with a “universal” fuel and ignition timing calibration. This calibration is intended to allow the vehicle to start and operate at part throttle, and is not optimized for full throttle performance. Do not operate the vehicle at heavy throttle or high RPM until a custom calibration tailored for your specific vehicle can be obtained from a competent tuner. A “wideband” exhaust oxygen sensor must be used to confirm proper air/fuel ratio. Vortech suggests a proper WOT air/fuel ratio range of 10.8-11.0:1 for 91 octane fuel.

STOP

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

iii

TABLE OF CONTENTS

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

TOOL & SUPPLY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

PARTS LIST (2002-2005 3.0L Lexus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi

1. PREPARATION/REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. OIL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3. OIL DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

4. ABS RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION . . . . . . .7

6. CHARGE COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

7. AIR INLET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

8.1 FUEL MANAGEMENT UNIT (FMU) RECALIBRATION (2003

Automatic Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

8.2 FUEL PUMP AND FMU INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .23

9. POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

10. ELECTRONIC CONTROL BOX INSTALLATION . . . . . . . . . . . . . . . . . . . .27

11. FINAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

This product is protected by state common law, copyright and/or patent. All legal rights therein are reserved. The design, layout, dimensions, geometry, and engineering features shown in this product are the exclusive property of Vortech Engineering, LLC. This product may not be copied or duplicated in whole or part, abstractly or fundamentally, intentionally or fortuitously, nor shall any design, dimension, or other information be incorporated into any product or apparatus without prior written consent of Vortech Engineering, LLC.

IMPORTANT NOTE

2001-2005 3.0L Lexus IS300

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

Before beginning this installation, please read through this entire instruction booklet and the Street Supercharger System Owner’s Manual which includes the Limited Warranty Program, the Warranty Registration form and return envelope.

Vor tech supercharger systems are performance improving devices. In most cases, increases in torque of 30-35% and horsepower between 35-45% can be expected with the boost levels specified by Vor tech Engineering. This product is intended for use on healthy, well maintained engines.

Installation on a worn-out or damaged engine is not recommended and may result in failure of the engine as well as the supercharger. Vortech Engineering is not responsible for engine damage.

Installation on new vehicles will not harm or adversely affect the break-in period so long as factory break-in procedures are followed.

For best performance and continued durability, please take note of the following key points:

1. Use only premium grade fuel 91 octane or higher (R+M/2).

2. The engine must have stock compression ratio.

3. If the engine has been modified in any way, check with Vortech prior to using this product.

4. Always listen for any sign of detonation (pinging) and discontinue hard use (no boost) until problem is resolved.

5. Perform an oil and filter change upon completion of this installation and prior to test driving

your vehicle. Thereafter, always use a high grade SF rated engine oil or a high quality synthetic, and change the oil and filter at least every 3,000 miles. Never attempt to extend the

oil change interval beyond 3,000 miles, regardless of oil manufacturer’s claims as potential damage to the supercharger may result.

6. Before beginning installation, replace all spark plugs that are older than 1-year or 15,000

miles with original heat range plugs as specified by the manufacturer and reset timing to factory specifications (follow the procedures indicated within the factory repair manual and/or as

indicated on the factory underhood emissions tag). Do not use platinum spark plugs unless they are original equipment. Change spark plugs every 20,000 miles.

TOOL & SUPPLY REQUIREMENTS

• Factory repair manual

• 3" hole saw

• 1/2" socket and drive set: SAE & metric

• 3/8-18 tap & handle

• Adjustable wrench

• Open end wrenches: 3/8", 7/16", 1/2", 9/16",

10mm, 12mm

• Metric Allen wrench set

• Center punch and a 5/8" tapered punch

• Fractional drill bit set

• Grinder (electric right-angle)

• 6 quarts (or what is specified in your owner’s manual)

SF rated quality engine oil, oil filter and wrench

If it has been 20,000 miles or more since your vehicle’s last spark plug change, then you will also need:

• Spark plug socket

• NEW spark plugs

2001-2005 3.0L Lexus IS300

Installation Instructions

Congratulations on selecting the best performing and best backed automotive

supercharger available today... the VORTECH® supercharger!

ENGINEERING, LLC

008110 SMALL SILVER DIE-CUT DECAL 2 008130 LICENSE PLATE FRAME, VORTECH 1 008444 S/C STRT INFO PKG ASY VORT 1 2E248-080 SUPERCHARGER V-5F SQ CW, LEXUS IS300 1 4LA020-010 INSTRUCTION MANUAL, IS300 1 4LA110-010 POWER STEERING COOLR ASY 1

8N006-025 COOLER, P/S 4-PASS PERMA/CL 1 8N100-001 NYLON MOUNTING KIT 1 7P375-312 3/8" BARB x 5/16" BARB REDUCER 2 7R004-003 STEPLESS CLAMP, 14.5-70 4 7U031-018 5/16" EFI FUEL HOSE HI-PSR 4'

4LA111-044 S/C MOUNT BRKT ASY, LEXUS IS300 1

2A017-462 SPACER, IDLER SMOOTH 6-RIB 1 2A017-501-153 SPACER, .50"OD x 1.538"L ALUM 1 2A017-750-08 SPACER, .75"OD x .1.437"L 1 2A017-875-13 SPACER, .875"OD x .895"L 5 2A046-100 BELT, GATES K061010 1 4FA016-171 DUST COVER (IDLER PULLEY) 2 4FH016-150 IDLER PULLEY, 6-RIB 3" FLANGED 2 4LA010-010 BRKT, SUPPORT IS300 1 4LA010-021 BRKT, LOWER SUPPORT IS300 1 4LA010-044 BRKT, 5/16" S/C MOUNT IS300 1 4LA017-011 SPACER, IDLER, 1.060"L IS300 1 7A375-100 3/8-16 x 1" G5 HHCS PLT 2 7A375-100 3/8-16 x 1" G5 HHCS PLT 1 7A375-178 3/8-16 x 1-3/4" HXHD G8 5 7A375-276 3/8-16 x 2-3/4" HXHD ZINC 1 7C010-016 M10-1.25 x 16mm, FLG HD, 10.9 1 7C012-040 M12-1.75 x 40mm HXHD BOLT, CL10.9 1 7C060-070 M6-1.00 x 70mm HXHD CL8.8 PLT 2 7C080-040 M8-1.25 x 40mm, SHCS, CL12.9 1 7C080-081 M8-1.25 x 80mm, HXHD, CL10.9 1 7E010-075 #12 x 3/4" SHT METAL SCRW, HEX 3 7F375-017 3/8-16 NYLOCK NUT 2 7J006-094 6mm WASHER SS 2 7K312-001 5/16"AN WASHER, PLATED 1 7K375-040 3/8"AN960 FLAT WASHER PLATED 12

4LA112-010 INLET ASY, LEXUS IS300

8H040-035 AIR FILTER, 3.5" FLANGE, G35 OFFSET 1 7U030-036 1/2" OIL DRAIN HOSE 0.75' 7P500-001 1/2" HOSE UNION 2 7R001-006 #6 STNLS HOSE CLAMP, NARROW 3 7U031-016 5/16" PCV/VAC RUBBER HOSE 2.5' 7R004-003 STEPLESS CLAMP, 14.5-70 4 7P312-050 5/16" HOSE MENDER 1 7P312-060 ELBOW, PLASTIC 5/16" x 90° UNION 1

4LA130-026 OIL FEED LINE ASY, IS300 1

7P125-004 1/8"NPT x 90° x -4 JIC FTG STL 1 7P125-005 1/8"NPT STR x -4 JIC FTG STL 1 7P125-034 1/8"NPT x 1/8"NPT STRT T 1 7P125-125 FTG, 1/8"NPT FEM x 1/8"BSPT MALE 1 7U100-055 TIE-WRAP, 7.5" NYLON 5 7U250-090-320 OIL FEED HOSE, 32" x -4 x 90° 1

4NZ101-068 FUEL PUMP ASY, INLINE 350Z 1

5W001-045 16-14GA RING TERM., .17" HOLE 1 5W001-032 1/4" WIRE LOOM 10' 5W001-011 16-14GA RING TERM. .26" HOLE 1 5W014-030 14GA STRD WIRE BLACK .5' 7E010-075 #12 x 3/4" SHT METAL SCREW, HEX 2 7P312-017 5/16" HOSE BARB TO M10 x 1.0mm 1 7P312-082 5/16" TEE HOSE BARB 2 7R003-027 ADEL CLAMP, 1-11/16" 2 7R004-001 STEPLESS CLAMP, 15.7-70 8

PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY.

7U031-0018 5/16" EFI HOSE, HI-PSR 5.5' 7U100-044 TIE-WRAP, 4" NYLON 10 7U100-055 TIE-WRAP, 7.5" NYLON 5 8F001-068 WALBRO INLINE FUEL PUMP, 68 GP 1

4NZ130-036 OIL DRAIN LINE ASY, 350Z 1

7P375-017 3/8"NPT x 1/2" BEADED HSE BARB 1 7R001-008 #8 STNLS HOSE CLAMP 2 7T560-001 CUTTER, 9/16" ROTABROACH 1 7T560-002 ARBOR, ROTABROACH 1 7U030-036 1/2" OIL DRAIN HOSE 1.5' 7U100-066 TIE-WRAP, 11" NYLON 5

4NZ238-088 FMU, 8:1 w/LINES, w/SPRING, 3 1

6Z010-101 FMU HOUSING (BLUE ANODIZED) 1 6Z010-111 FMU VALVE BODY (BLUE ANODIZED) 1 6Z010-131 COVER, FMU - GM 4.3 1 6Z020-130 SML DIAPHRAGM, FLUORO 1 6Z020-140 LRG DIAPHRAGM, FLOURO 1 6Z030-150 BRACKET, FMU 1 6Z040-160 PISTON, FMU 1 6Z050-191 FMU WASHER, 8:1 PLATED 1 6Z060-181 SHIM, FMU 1 6Z070-030 FMU 8:1 RING SPACER 1 6Z080-011 RETAINER, FMU SPRING GM 4.3 1 6Z090-010 SPRING, FMU GM 4.3 1 7C010-050 10-24 x .50" SHCS GR8 PLT 6 7C010-075 10-24 x 3/4" SHCS GR5 ZINC 4 7C024-025 10-24 x 1/4" PHILL HD 3 7E010-075 #12 x 3/4" SHT MTL SCRW, HEX 2 7P125-025 1/8"NPT x 5/32" HOSE, 90° 1 7P125-031 1/8"NPT x 90° x 5/16" BARB 1 7P125-032 1/8"NPT-STR, 5/16" BARB 1 7P156-082 5/32" TEE 1 7P312-005 5/16" FEM FUEL CNCT, STEEL 1 7P312-007 FUEL FTG, 5/16" GM x 5/16" HSE 1 7R004-001 STEPLESS CLAMP, 15.7-70 4 7U030-046 5/32" VACUUM LINE 7' 7U031-018 5/16" EFI FUEL HSE, HI-PSR 2.5' 7U031-018 5/16" EFI FUEL HSE, HI-PSR 1.25' 7U100-030 O-RING, FMU 1 7U100-096 ROLL PIN, 3/16" x 1/2" SS 1

5A003-130 ECU, UNICHIP QT, '02-'05 IS300 SAFE TUNE 1 8N201-330 CHARGE COOLR ASY, LEXUS IS300 1

4LA010-061 BRKT, HOOD LATCH SPRT IS300 1 4LA012-010 TUBE “A” S/C DISCHARGE IS300 1 4LA012-020 TUBE “B” S/C DISCHARGE IS300 1 4LA012-040 TUBE “D” S/C DISCHARGE IS300 1 4LA012-050 TUBE “E” S/C DISCHARGE IS300 1 4NZ012-020 TUBE, COOLER INLET, 350Z 1 7A250-074 1/4-20 x .75" HHCS PLTD 1 7A312-050 1/4-20 x 1/2" HXHD GR5 ZINC 2 7C008-050 #8-32 x 1/2" SHCS, ZINC 2 7E010-049 #10 x 3/4" HXHD SLF DRL SHT MTL 2 7F250-021 1/4-20 NYLOCK NUT ZINC PLATED 1 7J006-094 6mm WASHER SS 4 7P156-082 5/32" TEE 1 7R002-016 #16 SAE TYPE “F” SS HOSE CLAMP 2 7R002-040 #40 SAE TYPE “F” SS HOSE CLAMP 12 7R002-044 #44 SAE TYPE “F” SS HOSE CLAMP 2 7S250-025 ELBOW, 2.5"ID x 25° BLUE 5 7U030-046 5/32" VACUUM LINE 3' 7U133-090 RUBBER ELBOW, Ø1.0" x 90° 1 8D001-001 STD COMPRESS BYPASS VALVE 1 8H040-075 1" AIR FILTER BYPASS 1 8N010-210 BRKT, CLR MNT, IS300 1 8N101-350 CHARGE AIR COOLER, 350Z 1 7S300-275 REDUCER, 3.00" x 2.75" 2

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts

immediately.

2002-2005 3.0L Lexus

Part No. 4LA218-010SQ/018SQ

ENGINEERING, LLC

PARTS LIST

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

vii

8F101-350 RELAY ASY, 350Z FUEL PUMP 1

5W001-005 3/8" PLASTIC WIRE LOOM 8' 5W001-010 16-14GA FEMALE SLIDE INSULATED 2 5W001-016 RELAY, BOSCH 1 5W001-040 12-10GA FEMALE SLIDE INSULATED 2 5W001-046 16-14GA RING TERM. .33" HOLE 2 5W001-054 16GA FUSE HOLDER WITH WIRE 1 5W014-010 14GA STRD WIRE, RED, UL1015 7' 5W014-030 14GA STRD WIRE BLACK 1' 5W014-030 14GA STRD WIRE BLACK 7'

6Z170-040 10:1 RING SPACER ASY 1

PART NO. DESCRIPTION QTY PART NO. DESCRIPTION QTY.

IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts

immediately.

2002-2005 3.0L Lexus, cont’d

Part No. 4LA218-010SQ/018SQ

ENGINEERING, LLC

PARTS LIST

viii

This Page Left Intentionally Blank

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

A. Disconnect the negative battery cable. B. Remove the four 10mm headed fasteners

securing the plastic engine cover and set aside.

C. Disconnect the valve cover vent hose from

the air inlet assembly but leave it attached to the valve cover.

D. Using a 10mm socket and ratchet, remove

the factory air filter enclosure, air scoop, and ducting leading to the throttle-body and set aside. (See Fig. 1-a.)

E. Remove the MAF electronics from the previ-

ously removed intake ducting and set aside to be reused in a later step. (See Fig. 1-b.)

F. Detach the pressure solenoid from the plastic

air filter enclosure (a single 10mm head screw). Set solenoid and screw aside to be reinstalled in a later section. (See Fig. 1-c.)

1. PREPARATION/REMOVAL

Fig. 1-a

Fig. 1-b

Fig. 1-c

NOTE: It is a good idea to label the line connec-

tions to prevent confusion later.

G. Disconnect the ABS module harness plug

from the module. Using a 10mm wrench, loosen the ABS module retaining nuts. Remove the module from its mounting bracket. Using a 12mm wrench, remove the hardware securing the ABS module bracket. Remove the module mounting bracket from the frame rail and set aside. Be careful not to

lose the rubber stud mounts or the rubber bushing on the bottom of the module.

MAF ELECTRONICS

LEAVE CONNECTED

TO HARD LINE

H. Drain the engine coolant into a clean contain-

er and set aside. Remove the lower radiator hose located on the passenger’s side of the engine. Trim approximately 1" from the end of the hose that was attached to the radiator, and set aside. Remove the upper radiator hose and set aside to be reinstalled in a later step. Remove the thermostat housing. Rotate the thermostat housing 180° and reinstall. Disconnect the fan’s power connectors, radiator overflow bottle and remove the fan mounting hardware. Remove the engine fan assembly and set aside. Remove the upper radiator mounts/hardware and set aside. Remove the radiator and set aside. (See Fig. 1-d.)

I. Remove the four 5mm socket-head screws

retaining the cam sprocket cover and set the cover and hardware aside. Locate the plastic wire loom channel on the passenger’s side of the engine. Remove the wire loom from the channel. Remove the 5mm socket-head fastener securing the channel to the cylinder head. Cut the channel as shown. (See Fig. 1-e.) Install the supplied piece of flex loom onto the exposed section of wire and wrap with electrical tape. Reinstall the cam sprocket cover using the factory hardware.

NOTE: Automatic transmission vehicles will

need to disconnect the cooler lines running to the radiator. Cover any open line connections to avoid possible fluid contamination.

Fig. 1-e

Fig. 1-d

1. PREPARATION/REMOVAL, cont’d

THERMOSTAT HOUSING

ROTATED 180°

TUBE PREVIOUSLY

CONNECTED TO

PRESSURE SOLENOID

CUT LOOM HERE

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

Fig. 1-f

J. Remove the wire loom bracket secured to the

top of the water pump and discard. (See Fig. 1-f.) Remove the 10mm headed screw located just above and to the driver’s side of the previously removed bracket as shown. (See Fig. 1-g.)

K. Remove the 12mm headed bolt and wire har-

ness on the side of the water pump and discard. (See Fig. 1-g.)

L. Cut the small black cross-over tube located

just above the water pump where indicated. (See Fig. 1-f.)

M. Loosen the four water pump pulley retainers.

Un-tension the accessory drive belt and remove. Remove the water pump pulley retainers and pulley, setting them aside to be reinstalled in later step.

N. Remove the bolt securing the alternator to

the water pump. Remove the 12mm headed bolt just to the right (driver’s side) and down from the previously removed alternator bolt. Remove the 10mm headed bolt just above the alternator. (See Fig. 1-g.)

Fig. 1-g

1. PREPARATION/REMOVAL, cont’d

BOLT SECURING LOOM BRACKET

LOWER

W/P BOLT

ALT. BOLT

REMOVE

CUT TUBE HERE

PREVIOUSLY

SECURED

LOOM

BRACKET

REMOVE

10mm HEADED

SCREW

A. The supercharger uses engine oil for lubrica-

tion and must have an oil feed line connected to a filtered oil access on the engine.

B. Locate the oil pressure sending unit on the

driver’s side of the engine, just in front of and above the engine mount. (See Fig. 2-a.)

C. Disconnect and remove the pressure sender

and set aside to be re-installed later.

D. Locate the supplied oil feed assembly

(4LA130-026).

E. Install the supplied 1/8"BSP adapter into the

hole previously occupied by the oil pressure sender. Install the supplied 1/8"NPT street TEE into the BSP adapter. Orient the branch of the TEE so that it faces up. Thread the factory sending unit into the TEE as shown. (See Fig. 2-b.)

2. OIL FEED

Fig. 2-a (View From Below)

Fig. 2-b

OIL PRESSURE

SENDER

OIL PAN

1/8"NPT x #4 FLARE

FACTORY OIL

PRESSURE SENDER

1/8"NPT STRT TEE

BSP

ADAPTER

NOTE: The factory wiring harness may need to

be unclipped from the engine block to gain the necessary length to reach the repositioned sending unit.

NOTE: Pipe tape, paste or other sealant is not

recommended as it may loosen and cause blockage of the oil feed orifice resulting in supercharger failure. Use engine oil on the threads.

F. Install the supplied 1/8"NPT x #4 flare fitting

into the previously installed TEE. (See Fig. 2-b.)

G. Attach the straight end of the supplied oil feed

line to the #4 flare fitting previously installed and route up and over the engine valve cover.

H. Temporarily cover the open oil feed line end

to keep out debris until the connection is made to the supercharger in a later step.

I. Reconnect the factory oil pressure sender

wire.

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

A. To provide an oil drain for the supercharger, it

is necessary to make a hole in the intermediate oil pan.

B. Locate the factory oil drain boss on the pas-

senger’s side of the engine as shown. (See Fig. 3-a.)

C. Drill a 1/8" pilot hole into the center of the

boss. Using the supplied 9/16" rota-broach cutter and arbor, carefully machine a throughhole into the intermediate pan.

D. Tap the previously machined hole approxi-

mately 1/4" deep using a 3/8"NPT tap. Pack the flutes of the tap with heavy grease to hold the chips. Thoroughly clean the threads and hole with acetone or lacquer thinner.

E. Using a small amount of silicone sealer,

install the 3/8"NPT x 1/2" barb fitting into the previously tapped hole. Temporarily cap the fitting until the drain hose is connected in a later step. (See Fig. 3-b.)

F. Drain the engine oil and change the oil filter.

3. OIL DRAIN

Fig. 3-a

Fig. 3-b

NOTE: Pack the cutter with heavy grease and

DO NOT stop the drill motor until the rota-broach has been extracted from the pan This will help retain the cut out piece in the cutting tool.

NOTE: Automatic transmission vehicles only:

It may be necessary to temporarily remove the transmission cooler lines (see Fig. 3-a) from their mounting bracket to provide a clear path for drilling.

INTERMEDIATE

OIL PAN

OIL DRAIN LOCATION

LOWER

OIL PAN

3/8"NPT x 1/2" BARB FITTING

INTERMEDIATE

OIL PAN

ENGINE

BLOCK

Fig. 4-a

Fig. 4-b

Fig. 4-c

A. Locate the ABS module bracket removed in

Section 1. Remove the three spot welds that hold the side support to the main cradle. Separate the side support from the main cradle and discard. Drill the two lower spot weld locations to Ø3/16" and add an annitional Ø3/16" hole as shown. (See Fig. 4-a.)

B. (2001 Model Year Only, 2002 and Later

Skip to B-2.) —

1. Measure 2" back from the stud that previ-

ously secured the bottom of the ABS bracket and make a mark. At the previously marked location, measure down 15/8" from the top of a frame rail and make a second mark. Align the front and bottom edges of the bracket where the two marks intersect. Using the modified bracket as a template (see Fig 4-a) to mark the three hole locations on the frame rail. Drill the hole locations using a 1/8" drill bit. Secure the ABS bracket to the frame rail using the supplied selt-tapping hardware. Cut the factory stud that previously secured the ABS bracket flush wiith the frame. (See Fig. 4-b.)

(2002-2005 Model Years Only),

2. Measure 3.5" back from the stud that pre-

viously secured the bottom of the ABS bracket and make a mark. At the previously marked location, measure down 2.4" from the top of the frame rail and make a second mark. Align the front and bottom edges of the bracket where the two marks intersect. Using the modified bracket as a template (see Fig. 4-a) to mark the three hole locations on the frame rail. Drill the hole locations using a 1/8" drill. Secure the ABS bracket to the frame rail using the supplied self-tapping hardware. Cut the factory stud that previoisly secured the ABS bracket flush with the frame. (See Fig. 4-b.)

C. Remove the 10mm headed screw that

secures the plastic brake line separator and discard. Remove the brake lines from their plastic separator located on the frame rail. Slightly bend the lines running to the ABS module so that it may be repositioned to its new location. Secure the module to the relocated bracket using the factory hardware.

4. ABS RELOCATION

NOTE: Use caution when bending these lines.

Make bends as large as possible to avoid kinking.

NOTE: The preferred method of removing a

spot weld is the use of a spot weld cutting tool. However in this application, the use of an approximate sized drill or a right-angle grinder is acceptable.

D. Locate the ABS module harness.

Carefully split the plastic flex-loom exposing the wires from the ABS connector to the main harness on the shock tower. Separate enough length to reach the relocated ABS module and re-wrap the flex-loom. Reconnect the harness plug to the ABS module. (See Fig. 4-c.)

LINES SLIGHTLY BENT

RELOCATED

ABS MODULE

ABS HARNESS

SPOT WELD

NEW HOLE

LOCATION

SPOT WELDS

DRILLED

THROUGH

TOP OF FRAME RAIL

2" '01 MODEL YR

3.5" '02-'05 MODEL YRS

1-5/8" '01

MODEL YR

OF BRACKET

2.4" '02-'05

MODEL YRS

FACTORY

STUD

FRONT EDGE

OF BRACKET

BOTTOM EDGE

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

Fig. 5-b

A. Locate the S/C mounting bracket assembly

(4LA111-044.)

B. Using the M8 x 40mm socket-headed screw,

loosely attach the mounting bracket support block (4LA010-021) to the side of the water pump. (See Fig. 5-a.)

5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION

NOTE: For the following section, refer to Fig.

5-b for screw and spacer location. Do not tighten until all hardware is in place.

LOWER BRACKET

SUPPORT (4LA010-021)

M8-1.25" x 40mm

(7C080-040)

Fig. 5-a

3/8-16 x 1.75" SCREW, WASHER, & .895" SPACER (2A017-875-13)

M10-1.25 x 15mm

4LA010-010

UPPER SUPPORT

BRACKET

3/8-16 x 1" SCREW

& WASHER

3/8-16 x 2.75" SCREW, WASHER, DUST SHIELD, 3" SPOOTH IDLER, AND IDLER

SPACER (4LA017-011)

NO SPACER/FACTORY ALT. BOLT

(M10-1.25 x 50mm)

3/8-16 x 1" SCREW, WASHER, NYLOC NUT

Ø.50" x 1.538" SPACER (2A017-501-153) M6-1.0 x 70mm SCREW & WASHER

M6-1.0 x 70mm SCREW & WASHER

SPACER, LOWER SUPPORT (4LA010-021)

Ø.875" x 1.437" SPACER M8-1.25 x 80mm SCREW & WASHER

C. Using Fig. 5-b as a guide and working from

the bottom up, install all the applicable hardware and spacers into position as follows:

1. With the mounting bracket in position,

place the M8-1.25 x 80mm screw and washer through the mounting bracket,

1.437" spacer and into the lower water pump mounting hole.

2. Then install the factory alternator bolt

(M10-1.25 x 50mm) through the mounting bracket and into the alternator mount.

3. Next, install the M6-1.0 x 70mm screw

and washer through the mounting bracket support spacer (4LA010-021) and into the water pump.

4. Install the 3/8-16 x 2.75" screw and wash-

er through the dust shield, Ø3" smooth idler, idler spacer, and into the support spacer (4LA010-021).

5. Install the 3/8-16 x 1" screw and washer

through the mounting bracket and into the support spacer (4LA010-021).

6. Install the M6-1.0 x 70mm screw and

washer through the mounting bracket,

1.538" long spacer and into the upper water pump location.

7. Tighten the previously installed hardware.

Make sure all mounting surfaces seat flat against one another and no lines or wire, etc. are being pinched.

D. Loosely install the upper support bracket

(4LA010-010) to the S/C bracket using the two 3/8-16 x 1.0" screws, washers and Nylock nuts. Install the M10-1.25 x 16mm screw through the support bracket and into the cylinder head. (See Fig. 5-c.)

E. Evenly tighten the previously installed hard-

ware. Ensure the bracket is supported, but not pulled or the location of the S/C bracket is not changed.

F. Remove the blue plastic dust cap located on

the 1/2" oil drain fitting at the bottom of the supercharger. Attach the supplied 1/2" fabric braided oil drain hose to the supercharger drain fitting. Secure with a #8 hose clamp.

G. Secure the supercharger to the main bracket

using the five 3/8-16 x 1.75" screws, washers, and .896" long spacers. (See Fig. 5-b, 5-c.)

H. Reinstall the factory water pump pulley and

secure using the factory hardware.

5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, cont’d

Fig. 5-c

UPPER SUPPORT

BRACKET

M10-1.25 x

15mm SCREW

.895" LONG

SPACER

SEPARATE MAF HARNESS HERE

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

5. MOUNTING BRACKET AND SUPERCHARGER INSTALLATION, cont’d

I. Install a 12mm-1.75 x 40mm screw through

the dust shield, Ø3" smooth idler, idler spacer (.462" long piloted), and into the middle supercharger mounting boss. (See Fig. 5-d.)

J. Remove the blue plastic dust cap located on

the brass oil feed nozzle on the side of the supercharger. Thread the supplied 1/8"NPT x 90° fitting into the oil feed nozzle. Carefully tighten and clock the fitting as shown. (See Fig.5-e.) Use caution when tightening the oil feed fitting, as the nozzle may break if care is not exercised. Connect the previously installed oil feed line to the 90° fitting as shown. (See Fig. 5-e.)

K. Install the supplied drive belt as shown. (See

Fig. 5-f.)

Fig. 5-d

Fig. 5-e

Fig. 5-f

3" SMOOTH IDLER

IN MIDDLE POSITION

90° END OF SUPPLIED OIL LINE

1/8"NPT x 90°

NOTE: Use clean engine oil to lubricate fitting

threads. Pipe tape, paste, or other types of sealant are not recommended as it might loosen and cause blockage of the oil feed orifice, resulting in supercharger failure.

SUPERCHARGER

IDLER

WATER

PUMP

TENS.

POWER

STEERING

ALT.

CRANK

A/C

6. CHARGE COOLER INSTALLATION

Fig. 6-a

Fig. 6-b

Fig. 6-c

A. Locate the discharge assembly 8N201-330.

Use Fig. 6-a as reference.

B. Remove the 10mm headed screws securing

the plastic splash shield to the bottom of the car and set aside.

C. Using a Ø2.5 x 25° sleeve and #40 clamps

provided, secure Tube “A” onto the supercharger discharge. (See Figs. 6-a, 6-b.)

D. Secure the supplied bypass valve to Tube “A”

using the Ø1" x 90° elbow and two #16 hose clamps provided. Orient as seen in Fig. 6-b and install the supplied 1"ID filter. Attach a length of Ø5/32" vacuum hose to the bypass valve and route to the vacuum port on the intake manifold. Remove the factory vacuum cap from the manifold port and attach the previously routed vacuum line. (See Fig. 6-c.)

TUBE “A”

TUBE “B”

TUBE “E”

TUBE “D”

CHARGE COOLER

TUBE “C”

Ø2.5" x 25° SLEEVE

BYPASS VALVE

TUBE “A”

VACUUM LINE

TO BYPASS

VALVE

VACUUM PORT

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

6. CHARGE COOLER INSTALLATION, cont’d

Fig. 6-e

Fig. 6-f

Fig. 6-d

TUBE “B”

TUBE “C”

Ø2.5" x 25°

SLEEVE

Ø4.5" HOLE IN

SPLASH PANEL

Ø2.5" x 25°

SLEEVE

CAC

TUBE “C”

Ø2.5 x 25°

SLEEVE

E. Attach Tube “B” using a Ø2.5" x 25° sleeve

and #40 clamps provided to Tube “A” as shown. (See Fig. 6-d.)

F. A Ø4.5" hole will need to be cut in the driver’s

side splash panel to provide a path for the CAC discharge tube. Using a Ø4.5" hole saw or tool of choice, mark and drill the hole location shown. (See Fig. 6-e.)

Ø2.5" x 25° SLEEVE

TUBE “B”

OIL PAN

POWER STEERING COOLER PREVIOUSLY

ATTACHED TO CORE SUPPORT

ECU ENCLOSURE

10mm HEADED

SCREW

LINE BRACKET

CUT HERE

6. CHARGE COOLER INSTALLATION, cont’d

Fig. 6-g

Fig. 6-h

Fig. 6-i

G. Remove the three retaining screws at the top

of the grill. Unclip the bottom edge of the grill. Remove the grill and set aside.

H. Locate and remove the two 10mm headed

screws that secure the P/S cooler to the front core support. Disconnect the rubber P/S hoses from the steel P/S line assembly located near the P/S reservoir. Remove the power steering cooler and the steel P/S line assembly located on the driver’s side of the radiator and discard. (See Fig. 6-g.) To gain access to the assembly on the driver’s side, you will first need to temporarily remove the three 10mm headed retaining screws that secure the ECU enclosure and pull the enclosure upward to gain access to the 10mm headed screw that retains the line bracket to the top of the frame rail. Once you remove the line bracket, re-secure the ECU enclosure using the factory hardware. (See Fig. 6-h.)

NOTE: Leave the rubber lines connected to the

power steering pump.

I. Remove the two retainers securing the top of

the A/C condenser. Tilt the condenser back toward the engine (be careful not to damage the condenser).

J. Remove the bolt securing the hood latch

assembly to the core support. Cut approximately 9" from the bottom of this mount. (See Fig. 6-i.)

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

6. CHARGE COOLER INSTALLATION, cont’d

Fig. 6-j

Fig. 6-k

Fig. 6-l

CAC MOUNTING BRACKET

8N010-210

FACTORY HARDWARE

K. Secure the CAC (Charge Air Cooler) bracket

8N010-210 to the passenger’s side frame rail using the factory hardware as shown. (See Fig. 6-j.) Loosely install the charge cooler into its location. (See Figs. 6-j,6-k.)

L. Using the supplied 1/4-20 x .50 " hardware,

loosely attach the CAC to the mounting bracket.

M. Reinstall the A/C condenser, and secure

using the factory hardware.

N. Install one of the provided Ø2.5-25° sleeves

onto the CAC inlet and secure using #40 hose clamps. (See Fig. 6-e.)

O. Using a Ø2.5" x 25° sleeve and #40 clamps

provided, secure Tube “C” to the open end of Tube “B” and the 25° sleeve previously installed onto the CAC. (See Figs. 6-e, 6-f.)

P. To provide a path for the discharge ducting,

you must cut a Ø3" hole through the inner fender behind the passenger’s side headlight. Using the provided template, mark and drill the location. Take care not to damage the headlight assembly or wiring harnesses in this area. (See Fig. 6-l, 6-m.)

Q. Install one of the Ø2.5" x 25° elbow onto the

CAC discharge (passenger’s side outlet) and secure using the provided #40 hose clamp. (See Fig. 6-m.)

This Page Left Intentionally Blank

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

Template

This Page Left Intentionally Blank

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

6. CHARGE COOLER INSTALLATION, cont’d

Fig. 6-m

Fig. 6-n

Fig. 6-o

TUBE “D”

Ø2.5" x 25°

ELBOW

TUBE “A”

TUBE “B”

2.75"-3" REDUCER SLEEVE

TUBE “E”

MAF ELECTRONICS

R. Install the straight section of discharge duct

“D” up through the previously cut Ø3" hole. Attach the curved end to the previously installed elbow and secure using the provided #40 hose clamp. (See Fig. 6-m.)

S. Install one of the provided Ø3" x Ø2.75"

reducer sleeve onto the open end of duct “D” and secure using the provided #40 clamps.

T. Secure the remaining Ø3" x Ø2.75" reducer

sleeve to the throttle body using the supplied #40 hose clamp. (See Fig. 6-n.)

U. Secure the previously removed MAF electron-

ics to Tube “E” using the supplied 8-32 x .50" hardware. (See Fig. 6-o.) Make sure the OEM O-ring is in place and is undamaged.

NOTE: Rotate the previously installed 25°

elbow to allow best tube engagement and core support clearance.

Fig. 6-p

6. CHARGE COOLER INSTALLATION, cont’d

V. Connect the previously installed sleeves

using discharge duct “E” and two #44 hose clamps. (See Fig. 6-p.)

W. Locate the factory MAF harness. Carefully

split the plastic flex-loom exposing the wire to the sensor connector. Separate enough length to reach the new MAF sensor location, and re-wrap the flex-loom. Reconnect the harness plug to the MAF sensor.

TUBE “E”

Ø3" x Ø2.75"

REDUCER

Ø3" x Ø2.75"

REDUCER

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

Fig. 7-c

A. Locate the 4LA112-010 Air Inlet Assembly. B. Loosely install the supplied air filter onto the

supercharger inlet. Mark the two hole locations to be drilled in the filter. One hole approximately Ø5/16" in the center of the filter. The other hole should be approximately Ø1/2" and offset to clear the ABS lines. (See Fig. 7-a.)

7. AIR INLET INSTALLATION

Fig. 7-b

Fig. 7-a

SUPPLIED AIR FILTER

1/2" UNION

5/16" 90° ELBOW

LINE TO PRESSURE SOLENOID

LINE TO MOLDED FACTORY HOSE

PRESSURE

SOLENOID

LINE TO FILTER

MOLDED FACTORY HOSE

5/16" HOSE

MENDER

5/16" HOSE TO

PRESSURE

SOLENOID

RELOCATED

ABS MODULE

C. Install the two fittings into the end of the air

filter and re-install onto the supercharger inlet and secure. (See Fig. 7-a.)

D. Locate the pressure solenoid removed from

the plastic air filter enclosure in a previous step.

E. Secure the solenoid to the top of the passen-

ger’s side frame rail using the factory retainer as shown. (See Fig. 7-b.)

F. Using the supplied union and length of

Ø5/16" hose provided, connect the formed rubber hose (previously connected between the filter enclosure and the solenoid) to the vacuum port as shown. (See Figs. 7-b, 7-c.)

G. Connect the remaining portion of the Ø5/16"

hose between the Ø5/16" x 90° fitting previously installed into the air filter and open vacuum port on the pressure solenoid. (See Figs. 7-a, 7-b.)

NOTE: Thoroughly clean the inside of the filter

and inspect to make sure no material is left from the drilling process.

Fig. 7-g

7. AIR INLET INSTALLATION, cont’d

VALVE COVER BREATHER

1/2" UNION

1/2" HOSE

1/2" UNION

H. Using the supplied union and length of Ø1/2"

hose provided, connect the valve cover breather hose (previously connected to the factory air box) to the union previously installed in the supplied air filter. (See Figs. 7-a, 7-g.)

I. Attach the length of Ø5/32" vacuum hose to

the bypass valve and route to the vacuum port on the intake manifold. Remove the factory vacuum cap from the manifold port and attach the previously routed vacuum line.

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

8.1 FUEL MANAGEMENT UNIT (FMU) RECALIBRATION (2003 Auto)

NOTE: This step applies to Model Year 2003 automatic vehicles only! For all

others, skip the following and proceed with Section 8.2.

A. Remove the six allen-head screws on top of

the fuel management unit (FMU).

B. Remove the diaphragm and 8:1 disk and

ring from inside of the FMU.

WARNING: Do not remove the four

screws holding the valve body. Once taken apart, the valve would have to be replaced.

C. Install the replacement 10:1 ring (with

the notched part facing FMU body)

around the four screws inside the FMU. (The 10:1 components are larger in diameter than the 8:1).

D. Place the 10:1 disk inside the ring next to the

piston.

E. Install the new diaphragm and carefully line

up the holes to the body.

F. Place the spring retainer in the center of the

diaphragm with the spring between it and the cover. (See Fig. 8.1-a.)

G. Reinstall the FMU cover with the six allen-

head screws. Do not over-tighten the screws. The correct torque is 24 in/lb (2ft/lb).

8:1 RING SPACER 8:1 WASHER (Ø2.270") LARGE DIAPHRAM SPRING RETAINER SPRING

FCU COVER

Fig. 8.1-a

This Page Left Intentionally Blank

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

Fig. 8-a

A. Locate the rubber section of the fuel supply

line on the driver’s side frame rail as shown. (See Fig. 8-a.)

B. Cut the fuel line in approximately the middle

of its length. (See Figs. 8-a, 8-b.)

C. Using the FMU and mounting bracket as a

template, position the FMU as shown. (See Fig. 8-c.) Mark the two hole locations. Drill 1/8" pilot holes in the previously marked hole locations. Install the FMU using the provided #12 sheet-metal screws as shown. (See Fig. 8-c.) Cut the spring lock fittings off of the supplied FMU lines as close to the fitting as possible and discard.

D. Position the supplied fuel pump as shown.

(See Fig. 8-d.) Mark and drill the two pilot holes in the sub-frame support brace. Secure the fuel pump and fuel pump ground wire to the sub-frame support brace using the supplied adel clamps and #12 sheet metal screws. (See Fig. 8-d.)

E. (See Figs. 8-e, 8-f for reference.)

1. Attach the two supplied Ø5/16" hose barb

TEEs to the open ends of the previously cut factory fuel line.

2. Connect the hose from the FMU inlet port

on the previously installed FMU to the TEE connected to the line from the fuel tank. Connect a length of supplied hose from the branch of the same TEE to the fuel pump inlet port.

3. Connect the length of hose from the out-

let on the side of the FMU to the TEE attached to the line going to the fuel rail on the manifold. Connect a length of supplied hose from the branch of the same TEE to the fuel pump outlet.

NOTE; The following step should be completed in a

well ventilated area free of any ignition source.

NOTE; Spring lock fittings are not used in this

application

NOTE; When installing the fuel lines in this step,

install the supplied clamps simultaneously. However, do not clamp until all connections have been made and verified.

NOTE; Using a pair of locking pliers to pinch the

fuel line on the fuel tank side of your cut location to avoid draining the fuel tank. Use caution as there will be fuel drainage from the engine side of the cut.

Fig. 8-b

Fig. 8-c

Fig. 8-d

8.2 FUEL PUMP AND FMU INSTALLATION

TRANSMISSION

DRIVER’S SIDE

FRAME RAIL

STEERING

LINKAGE

FUEL LINE TO BE CUT

FMU

FMU MOUNTING BRACKET

SUPPLIED FUEL PUMP

1-11/16" ADEL CLAMPS

FUEL LINE FROM TANK

FLOW

GROUND WIRE

4. Verify that all line connections have been

made properly. Adjust all previously installed hoses and fittings so the lines route smoothly and are kept away from any sharp or moving parts. Tighten securely, all previously installed clamps at this time.

5. Connect the supplied length of Ø5/32"

vacuum line to the pressure port on the FMU. Route the line up underneath the intake manifold to the vacuum port on the intake manifold. Using the supplied Ø5/32" vacuum TEE, connect the line to the previously installed line going to the by-pass valve. (See Fig. 8-g.)

Fig. 8-e

8.2 FUEL PUMP AND FMU INSTALLATION, cont’d

Fig. 8-f

Fig. 8-g

VACUUM LINE

TO BYPASS

VALVE

VACUUM PORT

FACTORY FUEL LINE

TO INTAKE MANIFOLD

5/32" HOSE (CONNECTED

TO MANIFOLD PRESSURE)

INLET

FACTORY SUPPLY

LINE FROM FUEL

TANK

OUTLET

INSTALL AND TIGHTEN CLAMPS

USING STEPLESS

CLAMP PLIERS

INSTALL THE SUPPLIED SHEET-METAL SCREWS TO

HOLD THE FUEL MANAGEMENT UNIT AND FUEL PUMP

MARK AND DRILL HOLES

5/16" HOSE BARB TEES

SUPPLIED

FUEL PUMP

RED POWER WIRE

(FROM FUEL PUMP RELAY)

WASHERS ARE INSTALLED AND FITTINGS ARE TIGHT)

(VERIFY THAT COPPER

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

F. Mount the supplied fuel pump relay as seen

in Fig. 8-h using factory hardware. Using one of the supplied ring-terminals, connect the provided fuse holder to the (+) battery terminal. Connect terminals #85 and #30 to the fuse holder previously connected to the battery. Route the long black wire from terminal #87 to the postive (+) terminal on the previously installed fuel pump. Terminal #86 will be connected in a later step. (See Fig. 8-i “RELAY WIRING SCHEMATIC” for correct wiring.)

Fig. 8-h

Fig. 8-i

8.2 FUEL PUMP AND FMU INSTALLATION, cont’d

(+) TERMINAL ON

SUPPLIED FUEL PUMP

CONTROL

BOX

87a

8586

RELAY WIRING SCHEMATIC

(+) BATTERY

TERMINAL

A. Locate the power steering cooler relocation

assembly (4LA110-010). (See Fig. 9-a.)

B. Attach the supplied Ø5/16" rubber hoses to

the power steering cooler and secure using the stepless clamps provided.

C. Secure the power steering cooler to the A/C

condenser using the supplied nylon mounting kit. (See Fig. 9-b.)

D. Route the hoses around the driver’s side of

the radiator and towards the factory P/S hoses.

E. Using the supplied Ø3/8" to Ø5/16" barbed

reducers, two factory clamps and two stepless clamps provided, connect and secure the rubber lines to the factory P/S hoses. (See Fig. 9-c.)

F. Top off the power steering system reservoir

using the factory recommended power steering fluid.

G. Using the factory hardware, reinstall the radi-

ator and fan assembly. Install the upper and modified lower factory radiator hoses and secure using the original clamps. Refill the engine coolant system using the coolant drained in a previous step (provided it is in good condition). Automatic transmission vehicles reconnect the factory transmissiion cooler lines, you will need to wait until the installtion is complete before checking fluid level.

9. POWER STEERING

Fig. 9-a

Fig. 9-b

Fig. 9-c

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

A. Locate the factory ECU enclosure. Using a

10mm socket, remove the three retaining screws. Set the enclosure cover and hardware aside to be reinstalled later. (See Fig. 10-a.)

B. Disconnect the ECU harness connectors

located next to the ECU. To make room for the supplied ECU interface, you will need to remove the plastic connector cradle and discard. (See Fig. 10-b.) Reconnect the harness connectors. (See Fig. 10-c.)

C. Locate the supplied plug and play harness

connection. (See Fig. 10-d.) Make the appliicable ECU connections. Each connector plug is different from the others so there is only one possible location for each. (See Fig. 10-e.)

10. ELECTRONIC CONTROL BOX INSTALLATION

Fig. 10-a

Fig. 10-b

Fig. 10-c

Fig. 10-d

ECU ENCLOSURE

10mm HEADED

RETAINING SCREWS

HARNESS CONNECTOR

PLASTIC CRADLE

PLUG & PLAY

HARNESS CONNECTION

D. Once the connections have been made, gen-

tly push the unit down into the factory ECU housing next to the ECU. (See Fig.10-e.)

E. Locate the factory ECU cover previously

removed and cut a hole approximately Ø1/2" in the cover to allow the small 24-pin connector harness to pass through. Install the 24-pin connector harness through the ECU cover. Reinstall the ECU cover using the factory hardware. Using the supplied Velcro installation strip, install the control module to the ECU cover. (See Figs. 10-f, 10-g.)

F. Connect the 16-pin and 24-pin connectors to

the control module. Install the provided ring terminal onto the brown wires on the 16-pin harness. Route the brown wire to the location shown (see Fig. 10-f) and ground to chassis. Route the red and white wire to the fuel pump relay previously installed and connect to terminal #86 as shown previously in the “RELAY WIRING SCHEMATIC”. (See Fig. 8-i.on page 23)

10. ELECTRONIC CONTROL BOX INSTALLATIION. cont’d

Fig. 10-e

Fig. 10-f

Fig. 10-g

FACTORY ECU

SUPPLIED PLUG &

PLAY HARNESS

CONTROL

MODULE

16-PIN

CONNECTOR

24-PIN

CONNECTOR

BROWN

GROUND WIRE

FUEL PUMP

TRIGGER WIRE

P/N: 4LA020-010

11JUL07 v1.1 Lexus(4LAv1.1)

Fig. 11-a

A. Reconnect the battery. B. If your vehicle has gone over 20,000 miles

since its last spark plug change, you will need to change the spark plugs now before test driving the vehicle.

C. Check all fittings, nuts, bolts and clamps for

tightness. Pay particular attention to oil and fuel lines around moving parts, sharp edges and exhaust system parts. Make sure all wires and lines are properly secured with clamps or tie-wraps. (See Fig. 11-a.)

D. Check all fluid levels, making sure that your

tank(s) is/are filled with 91 octane or higher fuel before commencing test drive.

E. Start engine and allow to idle a few minutes,

then shut off.

F. Recheck to be sure that no hoses, wires, etc.

are near exhaust headers or moving parts and for signs of any fluid leakage.

G. PLEASE TAKE SPECIAL NOTE: Operating

the vehicle without ALL the subassemblies completely and properly installed may cause

FAILURE OF MAJOR COMPONENTS.

H. Recheck all fluid levels following the factory

recommended procedures at this time.

I. Test drive the vehicle by gradually working up

to full throttle and paying close attention to any abnormal sounds or engine detonation. If detonation is heard, discontinue heavy throttle usage until the necessary adjustment or repairs are made.

J. Read the Street Supercharger System

Owner's Manual and RETURN THE WARRANTY REGISTRATION FORM within thirty (30) days of purchasing your super- charger system to qualify.

11. FINAL CHECK

WARNING: Due to variances in each vehicle,

Vortech recommends that the vehicle get a “custom tune” from a local, reputable tuner. This kit is supplied with a “universal” fuel and ignition timing calibration. This calibration is intended to allow the vehicle to start and operate at part throttle, and is not optimized for full throttle performance. Do not operate the vehicle at heavy throttle or high RPM until a custom calibration tailored for your specific vehicle can be obtained from a competent tuner. A “wide-band” exhaust oxygen sensor must be used to confirm proper air/fuel ratio. Vortech suggests a proper WOT air/fuel ratio range of 10.8-11.0:1 for 91 octane fuel.

WARNING: Never operate your engine at full

throttle when the engine is cold. Always allow plenty of time for the oil to reach full operating temperature before running above 2,500 RPM. Full supercharger operating temperature is generally achieved only after the engine water temperature has been at the normal indicated operating range for two or three minutes.

DP/N: 4LA020-010 - v1.1 07/10/07

1650 Pacific Avenue, Channel Islands CA 93033-9901 • Phone: 805 247-0226

Fax: 805 247-0669 • www.vortechsuperchargers.com • M-F 8:00AM - 4:30PM (PST)

ENGINEERING, LLC

Vortech 2003-2005 Lexus 3.0L IS300 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual