PART 1: TRD CAI Install
The first step is to remove the the vacuum and ventilation hoses from the OE air intake. The Vacuum hose is held on with a spring clip, release it and firmly pull back to remove. The ventilation hose removes with a firm backward pull.
Loosen the 2 10 mm hose clamps and remove the air cleaner hose. Then remove the filter cover and filter (keep the filter). Remove the MAF (Mass Air Flow) sensor from the upper housing by lifting the retainer at the plug and then removing the wire retainer below it.
Unbolt the 2 10 mm bolts that hold down the lower half of the filter housing. One is located on the front right and the other on the rear left of the housing. Both bolts are attached to the housing with retainers so you will not lose the bolts. Then remove the lower half of the housing by removing the inlet duct from the sidewall and also the located guide pin to the lower front of the inlet.
Remove the inlet duct from the lower housing using a small plastic removal tool or small flathead screwdriver. Be carefull not to scratch the plastic but it will require some force to lift it off the tab.
This is how the new TRD inlet fits on the OE lower air cleaner housing. I found it easier to install the inlet in the sidewall first, then adding the lower housing.
The raised portion near my first thumb knuckle goes inside the sidewall. It is very flexible so you shouldn't need too much force to get it inside the sidewall.
Place the lower cleaner housing on the new inlet making sure that both tabs on both sides are connected to the inlet. To the left you can see the guide pin located in its proper position in the sidewall. Make sure that there are no wires under the housing and then bolt down the 2 10 mm bolts.
Remove the OE rubber gasket from the OE air filter. It will come off with no work, so don't pull too hard.
Reinstall the OE rubber gasket around the new TRD high flow airfilter making sure that you get it in the central grove all the way around. The gasket is the same on both sides so no worries about which side is up or down.
Place the TRD filter with the rubber gasket installed on the lower housing, noting the lean, make sure it is upright.
On the top of the new TRD upper housing on the back lefthand side is a small hole. insert the supplied rubber grommet in this hole with the flat side facing up. It was pliable enough not to need lubrication to install.
Using a phillips head screwdriver to remove both screws, remove the MAF sensor from the OE top housing and install it on the new TRD top housing using the OE screws.
Place the TRD upper housing over the OE lower housing and filter, noting the lean, and clip down with the four clip retainers on the housing sides.
Use gentle but firm and constant pressure to set the filter gauge into the grommet. Make sure to get it past the last of three ridges on the gauge inlet.
Hook the MAF sensor plug back into the MAF sensor and then connect the lower retainer into the new position below the MAF sensor.
Install the smaller of the two rubber boots around the engine air inlet using the smaller end and the smallest hose clamp. There is a notch in the rubber boot that should be oriented to allow the hose below the engine inlet to clear the rubber boot's central ridge. Tighten down the clamp. Then using the larger end of the larger boot with the largest hose clamp, attach the boot to the TRD upper filter housing outlet and leave lose.
Insert the new inlet pipe into the smaller boot with one of the two mid-sized hose clamps already on the boot. Orient the pipe so that the long extension pipe points straight back toward the cab of the truck. Now insert the other end of the pipe into the larger boot with the other mid-sized hose clamp already in place. Once it is properly oriented and the inlet pipe has about an inch inside of both boots, tighten down the three remaining hose clamps.
Reinstall the OE ventilation hose to the smaller pipe near the engine.
Reinstall the OE vacuum hose onto the new pipe from the air inlest pipe using the spring clip.
*If you download the PDF from http://http://www.trdsparks.com/install/PTR03-34070inst.pdf Website it includes a whole thing about remounting the vacuum hose connection and triming the hose. THIS IS NOT NECESSARY! In fact the install document Sparks sent did not include this part.*
*This completes the actual TRD CAI install, this next part allows you to modify the hood cover to fit over the TRD CAI in one of two ways. Option 1 involves cutting the cover using a supplied template and then remounting it. That one's fairly straight forward. Option 2 involves lifting the cover position about 2 inches higher with 4 spacers. This is the method I choose and I have described it below.*
Unbolt the 2 hood cover holding pins and 2 bolts holding the hood cover bracket in the rear with a long sleeve 10 mm socket.
As you can see, the hood cover bracket has different length connector arms to help you orient it correctly on reinstall. Also, the rollers go toward the front of the vehicle.
The TRD kit includes 4 spacers, the rear 2 are sleeves which you insert the supplied bolts and washers on. The order from top to bottom is bolt > washer > bracket arm > sleeve. Bolt both down.
The front spacers have a double threaded insert, this end goes into the engine and then the pins screw into the top, tighten it all down.
Find a spot near the air filter housing side of the hood, clean it and mount the TRD air filter sticker.
And that is how to install the TRD Cold Air Intake System using Hood Cover Spacers. Enjoy!
PART 2: TRD Dual Exhaust Installation
Remove the V-band clamp from the tail pipe/muffler connection with a 12 mm socket and discard it. Seperate the two by pushing rearward on the tail pipe and then remove it from the rear rubber hanger being careful to clear any wiring that is on the top of the rear axel assembly.
Soak all four catalytic converter flange bolts with a libricant (I used good old WD-40). Remove the 4 14 mm bolts that hold the 2 muffler pipes to the 2 catalytic converter pipes. Save these bolts as you will need them later.
Once the connections to the OE muffler have been removed, gently release the muffler from the the 2 forward rubber hangers one at a time. Lay the front of the muffler down on the ground (if not lifted). Leave the rubber hangers in place.
Using your foot as a brace on the back end of the muffler, pull it forward to release it from the rear rubber hanger. Once its released remove the rear rubber hanger.
There is an orange boot in the kit which you will place the rear muffler hanger boot into.
Take the boot/hanger combination and with the enclosed end facing the muffler, install it onto the rear hanger of the new TRD muffler.
There is a small heat sheild on the rear passenger side over the place where the OE tailpipe was, it is the rear most heat sheild on the truck. Use a 10 mm socket to release the two bolts and remove the sheild, keeping the 2 bolts.
The new TRD heat sheild goes right into the same place. The front end needs to clear the wires on the underside of the truck bed. make sure that the slotted hole on the TRD sheild is the one in the rear and then bolt it on with the 2 OE 10 mm bolts.
Locating the holes for the new right side rubber hanger bracket (included in the kit) is somewhat hard if you don't realize that the hanger, unlike all the OE ones on the truck, faces side-to-side and not front-to-back. There is also an additional OE bracket that you can see hanging down from the spare tire bracket, which partially covers the larger tab hole. Once you find the two holes insert the tab into the larger hole and the bolt in the smaller, then tighten it with the supplied nut.
Now its time to hang the TRD muffler. Its essentially a reverse of taking out the OE muffler. Attach the boot/hanger combo to the rear hanger on the truck making sure to seat it over the knob at the end of the hanger.
Attach the front of the TRD muffler with the 2 OE rubber hangers.
Now using the 4 OE bolts removed earlier, attach the two catalytic converter pipes to the 2 TRD muffler inlet pipes. Always use a torque wrench when dealing with engine/body supports. Tighten the bolts alternating every several turns to ensure proper seating. If done properly the muffler should pull itself into the proper position.
Install the 2 gaskets on the two rear pipes of the TRD muffler.
Place both pipes over the rear axel going in from the back of the truck. Both pipes will rest on the passenger side of the axel and as always, make sure you clear all wires. leave the bubble wrap on the tips to prevent scratching. Once both are in position attach them to the rubber hangers making sure to clear the end of the retaining knobs. Making sure to clear the gaskets placed on the muffler outlet pipes,place the tailpipes over the muffler outlets with the new V-band clamps over the tailpipe ends. Use a large adjustable plyer to hold the clamp ends close till you can thread the supplied 12 mm bolt/washer combination into the other side. Once you begin to tighten the V-band clamps down you will notice the tailpipe outlets moving into their proper places. Make sure not to bump the polished ends against the body, even with the bubble wrap in place.
With both new V-band clamps in place and torqued down at a 45 degree angle the installation is complete.
And here is my new driverside TRD tip poking out. It sounds deeper and throatier and has a strong "purrrrr" at idel and roars at the first acceleration and each upward shift! Toward the top of each shift point or while crusing in a gear it is mild yet noticible. The install was incredibly easy with a crawler and a raised curb! The hardest parts were needing a BIG wrench to loosen the flange bolts and the fact that you had to switch from 4 different socket sizes.
msxjw has already recorded the sounds and sights of the vehicle in operation with the TRD exhaust so here is that:
TRD CAI and Dual Exhaust
Single vs Dual Exhuast
DIY: TRD CAI and Dual Exhaust Install
Linear Mode
