POWER'S TURBOCHARGER KIT

ＩＮＳＴAＬＬＡＴＩＯＮ　ＩＮＳＴＲＵＣＴＩＯＮ GUIDE

ｆｏｒ　ＭＲ－Ｓ　（ＺＺＷ３０）　１ＺＺ－ＦＥ

Contents Page

1. Prior to the Installation 2

2. Attentions 3

3. Components List 4 to 5

4. Figure for Components 6

5. Removal of the Stock Parts and Modification 7 to 11

6. Turbocharger Installation 11 to 14

7. After the Installation 15

ISSUES ON 1st JULY 2000　COPY & REPRODUCTION FORBIDDEN

REVISED ON OCTOBER 2003

　　　　　　　　　　　　　　　　　　POWER ENTERPRISE CO., LTD.

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1. PRIOR TO THE INSTALLATION

･Read this installation instruction guide before the installation. Fit and remove the stock parts

manual and this guide.

･The installation of this MR-S Turbo Kit is basically onto the normal vehicle.

･ We d o n o t g u a ra n t e e t h e f u n c t i o n , p e rf o r ma n ce a n d sa f e t y o f t h i s M R - S Tu r b o K it i f y o u i n st a l

specified.

･We accept no responsibility for the damage you suffer when you or other persons modify, dismantle and

MR-S Turbo Kit and the components in the vehicle (engine) not specified.

･This guide and the components are subject to change without notice.

･Keep this guide in order to read at any time.

･After the installation, the engine check light is ON after a while when starting the engine. There is no problem

i f th e en gine che c k l ig ht is O FF w he n st arti ng th e Ifent he

gine
e n. gin e ch e ck l igh t i s O N so on af t er st a rt in g

engine, you need to have your vehicle checked by a car dealer.

･The maximum boost pressure of this MR-S Turbo Kit is set within 0.4kg/cm2. You need to reprogram the ECU i

work this turbo kit at more than 0.4kg/cm2.

･ The calorific value of the engine increases by use of this MR-S Turbo Kit. You need to raise the heat value

the ignition plug.

･Use unleaded high-octane gasoline.

･When you run a car excessively with this turbo kit, idle the engine for a while to fully cool down the turbocharger.

･Use engine oil for a turbocharged engine, excellent in heat resistance.

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2. ATTENTIONS

･You can install this MR-S Turbo Kit in TOYOTA MR-S (ZZW-30) 1ZZ-FE engine only.

･Handle this MR-S Turbo Kit carefully. Do not drop or give a strong shock to this turbo kit.

･Ask the service technician to install this turbo kit.

･Read this installation instruction guide prior to the installation.

･Confirm the components of this turbo kit following the parts list(page 4).

･Use the original bolts and nuts not included in this turbo kit.

･It is terribly dangerous to modify this turbo kit as the devices around this turbo kit are possibly damaged or the safety is

possibly lost.

･A part of the original parts should be modified when installing this turbo kit.

･Remove the minus terminal of the battery prior to the installation.

･Tighten the bolts and nuts certainly with proper tools.

･Protect the connection of the pipes and hoses from oil. Remove oil if it sticks to the connections.

･Take care of the original parts to be removed at the installation not to be damaged and lost, and mark them to

wrong installation.

･Protect the pipes, hoses and turbocharger from any dust. It is afraid that it may damage them.

･Take care of the vehicle after the installation and check each part following the service manual.

･When you handle the parts of fuel system, let fresh air into the place you are working to install in order to protect from

fire.

･The products produced by POWER ENTERPRISE have been designed for off road v

products are legal for sale and use only on off road vehicles which may never be driven on the public highway.

*Contact promptly the shop you purchased this MR-S Turbo Kit if the model of your vehicle is not suited to this turbo kit

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 COMPONENTS LIST for MR-S TURBO KIT

No. NAME AMOUNT PART NO.

1 PE1215S Turbocharger Assembly 1 1310-PE1215S
2 Actuator Binder (assembled into actuator) 2 1321-PE-CR
3 Positioner (assembled) 1 1322-PE-CR
4 Bolt (M4x0.7 L=6 assembled) 4 9-M4x0.7 06B
5 Bolt (M4x0.7 L=8 assembled) 2 9-M4x0.7 08B
6 Actuator Spring K=0.3 (assembled) 1 1333-PE-CR
7 Exhaust Manifold 1 1301-TT111
8 Exhaust Outlet Pipe 1 1302-TT111
9 Air Inlet Pipe 1 1351-TT111
10 Air Outlet Pipe 1 1 1352-TT111
11 Air Outlet Pipe 2 1 1353-TT111
12 Adaptor of Air Flow Censor 1 1354-TT111
13 Air Impulse (air cleaner) 1 AI-T344
14 Air Cleaner Bracket 1 1373-TT111
15 Wire 　 　 1 　 　
16 Silicone Hose φ70 L=80 1 13-φ70x80-SIL
17 Silicone Hose φ50 L=80 2 13-φ50x80-SIL
18 Silicone Hose φ50-φ60 L=80 1 13-φ50-60x80-SIL
19 Silicone Hose φ70-φ80 L=80 1 13-φ70-80x80-SIL
20 Hose Band φ70-φ90 2 8-φ70-φ90
21 Hose Band φ70-φ90 2 8-φ70-φ90
22 Hose Band φ50-φ70 6 8-φ50-φ70
23 Hose Band φ22-φ30 4 8-φ22-φ30
24 Oil Inlet Hose L=1050 1 1317-TT111
25 Oil Pressure Adaptor 1 1411-TT111
26 Oil Inlet Banjo φ10 1 1318-TT111
27 Oil Inlet Bolt Banjo M10x1.5 1 1412-TT111
28 Aluminum Washer 2 7-φ10x1-AL
29 Heat Blocking Sheet (100x1000) 1 5-SHEET
30 Wrap Band (150mm) 8 6-BAND-150
31 Blow-by Hose φ15 L=800 1 1319-TT111
32 Oil Return Hose φ19 L=530 1 1316-TT111
33 Oil Return Pipe 2 1314-ON211B
34 Oil Return Flange 1 1315-TT111

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35 Turbocharger Exhaust Gasket 1 1361-TT111
36 Turbocharger Gasket Out 1 1362-TT111
37 Oil Gasket Out 2 13-15196-69F00
38 Pressure Regulator Assembly 1 1810-TT111
39 Pressure Regulator Binder (assembled) 1 1811-TT111
40 Pressure Regulator Shim (assembled) 1 1812-TT111
41 Adaptor of Surge Pressure 1 1821-TT111
42 Washer φ16 1 1822-TT111
43 Hose of Surge Pressure φ4 L=120 1 1346-TT111
44 Band φ9-φ11 1 8-φ9-φ11
45 Pressure Regulator Adaptor 1 1830-TT111
46 T-joint Hose φ8-φ4-φ8 1 8-φ8-φ4-φ8J
47 Hose of Surge Pressure φ4 L=2000 1 1345-TT111
48 Cap 　 　 1 1341-TT111
49 Knock Sensor Connector 1 1831-TT111
50 Outlet Bracket 1 1371-TT111
52 Stud M8x1.25 L=36 8 9-M8x1.25-36B
53 Nut M8 　 6 9-M8-SUS-NUT
54 Bolt M8x1.25 L=25 2 9-M8x1.25-25B
55 Bolt M10x1.25 L=25 1 9-M10x1.25-25B
56 Bolt M10x1.25 L=40 3 9-M10x1.25-40B
57 Heat Insulator 1 1375-TT111
58 Oil Return Hose Clamp 1 1372-TT111
59 Nut M8 　 2 9-M8-NUT
60 Bolt M6x1.0 L=15 2 9-M6x1.0-15B
61 Hose Band φ17-φ25 1 8-φ17-φ25
63 Bolt M6x1.0 L=18 1 9-M6x1.0-18B
64 Bolt M6x1.0 L=18 3 9-M6x1.0-18B
65 Spring Washer M10 4 4-M10-SW
66 Bottun Bolt M6x1.0 L=12 1 9-M6x1.0-12BB
67 Bottun Bolt M6x1.0 L=8 1 9-M6x1.0-8BB
68 Straight Joint φ8-φ6 1 8-φ8-φ6-J

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5. REMOVAL OF THE STOCK PARTS AND MODIFICATION

*Follow the service manual.

(Use the stock gaskets, bolts and nuts which are not provided in the MR-S Turbo Kit.)

5-1 Fuel Pump Assembly Removal

NOTE: KEEP EXTINGUISHER BY YOUR SIDE TO PREVENT FIRE.

(1) Remove the circuit opening relay in the relay box

in the engine room.

(2) Start the engine, and the engine stops by itself.

Then turn the ignition to the OFF position.

(3) Disconnect the minus side of the battery terminal.

(4) Install the circuit opening relay.

(5) Remove the fuel tank cap and release the pressure

inside the tank.

(6) Remove the package tray panel behind the driver’s seat.

(7) Remove the fuel tank cover and separate the connector

of fuel pump.

(8) Separate the fuel evaporation tube.

NOTE: DO THE WORKS ABOVE BY YOUR HANDS.

DO NOT USE ANY TOOL.

PROTECT THE HOLE OF THE FUEL TANK FROM

SMALL DUST BY USING SHEETS.

(9) Separate the fuel tank main tube.

(10) Remove the fuel pump assembly.

(11) Take off the clip of the fuel suction plate with a screwdriver.

(12) Separate the connector, and remove the fuel suction plate.

(13) Remove the fuel pressure regulator.

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5-2 Fuel Pressure Regulator Installation

(1) Remove the O-ring from the stock fuel pressure regulator

and fit the O-ring into the provided adaptor (No.45) of

the fuel pressure regulator.

(2) Fit the adaptor into the fuel tank filter.

NOTE: APPLY GASOLINE TO THE O-RING NOT TO BE　TWISTED.

(3) Fit the provided fuel pressure regulator assembly (No.38)into the adaptor.

NOTE: Same as the above.

5-3 Fuel Suction Plate Modification

(1) Make a φ16 hole in the upper side (see the following figure) of the fuel suction plate.

(2) Make a φ20 hole in the lateral side (see the following figure) of the fuel suction plate.

(3) Shave off the support pipe holding the stock fuel pressure regulator as the dotted line

of the following figure.

NOTE: DO NOT SHAVE OFF EXCESSIVELY.

　　

5 -

Insta

F i t

ada

p r e

into

of th

plate

5 -

Asse

Cons

(1) Put the provided band (No.44) and hose (No.43) on the pressure regulator.

(2) Fit the bottom hole of the fuel pressure regulator and theφ20 hole of the fuel suction plate with two

tyraps (cable ties).

NOTE: NO BEND IN THE HOSE.

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(3) Join the connector and fit the fuel suction plate.

NOTE: CHECK THE SUPPORT PIPE PRESSING DOWN THE FUEL PRESSURE REGULATOR.

5-6 Fuel Pump Assembly Installation

(1) Install the fuel pump assembly.

(2) Connect the fuel tank main tube.

(3) Connect the fuel evaporation tube.

NOTE: NO SCRATCH AND SMALL DUST ON THE CONNECTIONS OF PIPES

AND CONNECTORS.

AFTER THE INSTALLATION OF THE PARTS ABOVE, CHECK THEM TO BE

CERTAINLY FITTED BY PULLING LIGHTLY THE CONNECTORS AND PIPES

5-7 Pressure Hose of Intake Manifold Installation

(1) Cut the canister purge hose, and fit the provided T-joint

(No.46) between the hoses.

(2) Fit the provided hose for surge pressure (No.47) into

the T-joint, route the hose through the hole

for the harness at the right side of the car

(the side of the driver’s seat), hole the rubber part of

the fuel tank cover, route the hose through that hole,

and fit the hose into the adaptor (No.41).

NOTE：AFTER THE INSTALLATION OF THE HOSE,

CHECK THE HOSE TO BE CERTAINLY

FITTED BY PULLING LIGHTLY THE HOSE.

NO BEND IN THE HOSE.

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(3) Install the fuel tank cover and then the package tray.

(4) Close the fuel tank cap.

NOTE: FIX THE HOSE (NO.47) NOT TO MOVE BY TYRAP.

5-8 Oil Pan Removal

(1) Drain the engine oil.

(2) Remove the oil pan.

NOTE: LOOSEN THE BOLTS OUTSIDE FIRST AND THEN DIAGONALLY.

REMOVE THE OIL PAN WITH A SEAL CUTTER (special tool).

5-9 Oil Pan Modification and Installation

(1) Make a φ18 hole and aφ8.5 hole in the oil pan.

(See the figure).

(2) Fit the provided oil return flange (No.34) into the inside

of the oil pan, put the provided gasket (No.37) between

the outside of the oil pan and the provided oil return pipe

(No.33), and then fix the oil return pipe with two provided

nuts (No.59).

(3) Seal the flange face of the oil pan perfectly with sealant.

(4) Fit the oil pan.

NOTE：TIGHTEN THE BOLTS INSIDE FIRST

AND THEN DIAGONALLY.

DO NOT FEED OIL FOR THE OIL PAN

FOR ABOUT ONE HOUR AFTER SEALING.

5-10 Knock Sensor Connector Installation

(1) Remove the stock knock sensor connector, fit the

electrotap of the provided knock sensor connector

(No.49) into the stock knock sensor harness.

NOTE：CHECK THE ELECTROTAP TO BE

CERTAINLY FITTED.

(2) Fit the provided knock sensor connector (No.49) into

the knock sensor.

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5-11 Oil Pressure Switch Removal and Adaptor Installation

(1) Separate the connector of the oil pressure switch.

(2) Remove the oil pressure switch with 24mm deep socket wrench.

(3) Install the provided oil pressure adaptor (No.25).

NOTE: THE DIRECTION OF THE SCREWS SHOULD BE RIGHT SIDE (AIR CLEANER SIDE)

FROM THE SIGHT OF THE FRONT OF THE VEHICLE.

(4) Install the oil pressure switch.

NOTE: APPLY SEALANT ON THE SCREWS OF THE OIL PRESSURE SWITCH.

5-12 Exhaust Manifold Removal

(1) Remove the exhaust manifold insulator.

(2) Separate both (right and left side) O2 sensor connectors and remove both O2 sensors.

NOTE: USE THE O2 SENSOR SOCKET WRENCH NOT TO DAMAGE O2 SENSORS.

(3) Remove the exhaust manifold bracket.

(4) Remove the exhaust pipe.

(5) Remove the exhaust manifold.

NOTE: LOOSEN THE NUTS OUTSIDE FIRST AND THEN DIAGONALLY.

5-13 Air Cleaner Hose Removal

(1) Loosen two clamps and remove the air cleaner hose.

(2) Remove the air flow sensor.

(3) Remove the air cleaner box.

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6-1 Exhaust Manifold and Turbocharger Installation

(1) Fit the provided exhaust manifold (No.7) temporarily where the stock exhaust manifold was fitted.

(2) Fit two provided stud bolts (No.52) into the exhaust manifold (upside).

(3) Fit provided four stud bolts (No.52) into the exhaust gas outlet side of the exhaust housing of the provided

turbocharger (No.1).

(4) Put the provided gasket (No.37) between the turbocharger and the provided oil return pipe (No.33),

and fix them with two provided bolts (No.60, M6x1.0, L=15).

NOTE: THE DIRECTION OF THE OIL RETURN PIPE SHOULD POINT LEFT FROM

THE DRIVER VIEWPOINT.

(5) Put the provided gasket (No.35) between the exhaust manifold and the turbocharger, and fit

the turbocharger temporarily.

(6) Tighten the bolts and nuts.

6-2 Outlet Pipe Installation

(1) Fit the provided gasket (No.36), and temporarily the provided outlet pipe (No.8,

using four provided No.53 nuts).

(2) Move the stock manifold bracket from outside to inside (see the following figure).

NOTE: REMOVE THE MANIFOLD BRACKET AT THE PASSENGER SEAT SIDE.

(3) Fit the provided outlet bracket (No.50) into the stock manifold bracket, and connect the outlet pipe

and the muffler.

(4) Tighten the bolts and nuts.

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6-3 Air Outlet Pipe Installation

(1) Install the provided air outlet pipes (No.10 and 11) following

the figure on page 6.

(2) Remove the ventilation hose, and fit the provided cap

(No.48) into the pipe of the surge tank side with

the provided band (No.61)

6-4 Oil Inlet Hose Installation

(1) Fit the provided oil inlet hose (No.24) into the turbocharger.

(2) Fit the oil inlet hose into the provided oil pressure adaptor

(No.25).

NOTE:：FIX THE OIL INLET HOSE NOT TO SWING USING

WITH TYRAP.

WRAP THE PART TOUCHING THE OIL INLET

HOSE WITH THE PROVIDED SHEET (NO.29,

100x200) TO PROTECT THE HOSE FROM HEAT,

AND FIX IT WITH WIRE.

6-5 Oil Return Hose Installation

(1) Connect the oil return pipe and the pipe fitted into the oil pan

with the provided oil return hose (No.32).

(Use two provided No.23 bands.)

NOTE：FIX THE HOSES WITH THE PROVIDED CLAMP

(NO.58) NOT TO TOUCH THE DRIVE SHAFT.

WRAP WHOLLY THE OIL RETURN HOSE WITH

THE PROVIDED SHEET (NO.29, 100x500), AND FIX

THE HOSE WITH WIRE.

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6-6 Air Inlet Pipe Installation

(1) Fit the provided air inlet pipe (No.9) following the figureon page 6.

(2) Fit the stock air flow sensor into the provided adaptor of the air

flow sensor (No.12).

(3) Fit the adaptor of the air flow sensor into the air inlet pipe.

(3) Fit Air ImpulseⅡ(air cleaner) into the adaptor of the air flow

sensor.

(5) Join the air flow sensor connector.

6-7 Blow-by Hose Installation

(1) Fit the provided blow-by hose (No.31) into the pipe of the head cover where the ventilation hose was fitted.

(2) Fit the other side of the blow-by hose into the provided air inlet pipe (No.9).

6-8 O2 Sensor Connector

Wrap the connection of the left (passenger seat side) O2 sensor with the provided sheet (No.29).

6-9 Heat Insulator Installation

Fit the provided heat insulator (No.57) into the exhaust housing of the turbocharger.

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AFTER THE INSTALLATION

(1) Replenish engine oil.

(2) Check any oil leakage.

(3) Check any slack of each part.

(4) Check any part not installed. If any, look over the installation again.

(5) Check the following clearances not to touch each other when driving.

Oil return hose and drive shaft

Oil return hose and exhaust manifold

Oil inlet hose and throttle valve, etc.

(6) Start the engine, and then check any smell, sound, touch and leak.

Use left tyraps to hold the hoses not to move.

(7) When you excessively run a car with this MR-S Turbo Kit for a long time,

for example, at circuit racings, remove the insulator of the engine hood and

fully cool down the engine room.

307 Nakajima

Fuji-shi, Shizuoka 416-0907

PHONE: 0545-66-0707

F A X: 0545-66-0708

Website: http://www.power-enterprise.co.jp

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