Need help from someone who's installed TRD supercharger on 80 series

[Aliveiride]

I removed the SC from 96 LX450 to send it out to be serviced (unknown # of miles on it and Eaton recommends service at 60K intervals) and I'm having problems re-installing it. I did not originally install the kit and while I enjoy the benefits of added HP, I am amazed how s***ty the design of this kit is.

Issue #1: I replaced my main engine harness with a new one since there were a lot of cracked wires and broken connectors as well as half-assed repairs from previous owners. Following the instructions for the SC install it seems like the only mod needed for the harness is to break out the TPS & IAC connectors and the 10 wires that go to them and re-route them to the moved throttle body. I just cut into my new $460 harness and there is no way those wires are making it to the throttle body. 2 of the 10 wires are spliced onto a larger wire in the main harness which means I can only peel the wires out of the harness back to that splice, which I did, and the connectors are still about 4 inches from the throttle body. My gut is telling me to do it right and completely disassemble the firewall portion of the harness and bring the throttle body connectors out of the harness in the same location in the harness where the MAF wires come out and not stretch them across the top of the valve cover like the instructions show. Has anyone done it this way? Other than the 2 spliced wires I encountered, are there more splices further back in the harness that pose a problem?
Issue #2: The 1-1/2" nipple on the throttle body adapter does not line up with the bypass nipple on the Kazuma piece. Seems stupid considering these parts came in the kit together,they should line up or at least be close. They are so close they almost touch end to end but they are more than a 1/4" off of lining up. The hose is going to be kinked/offset if I leave it this way. The only solution I can think of is to drill out the clearance holes in the Kazuma piece and try to shift it on the SC studs a bit until the nipples line up and the hose can be straight. The hose I removed was mangled and I'm sure this offset was the cause. Did anyone else have this issue?

 

[1973Guppie]

issue one, most people have extended the harness, me included, you should be able to find more info on this by searching.

issue two, no idea, can you post pics?

 

[NLXTACY]

Yeah just splice a length of wire using butt connectors. No big deal.

 

[beachcomberspi]

#1 I know I took the harness back to the firewall before it would reach. Can you make the harness longer by extending all of them for the slack you need? I've seen it done.
#2 sounds like poor quality control and I don't have any thoughts. Cheers!

 

[george_tlc]

^1

Yep, extend the TPS/IAC wires - much easier than ripping into the harness. Of course that presumes you can splice extension wires reliably (either you are really good at soldering or you have a good crimper). Use heatshrink tubing with the internal adhesive liner to get a nice water proof cover over the solder/crimp area.

The short bypass hose is a pain in the arse and yes, it does not line up exactly. Great mold design... (not). The ones I've done weren't too far off, but they certainly weren't perfect. Maybe a piece of silicone hose would work better (more pliable).

Here's my install writeup from many years ago, might help you -> Kazuma Supercharger Install

cheers,
george.

 

[Aliveiride]

Awesome, thanks for the input.

I think extending the wires from their current location is probably a wise decision. I really wasn't excited about disassembling the portion of the harness with the plastic support and heat shield tape. I can scavenge the correct wires for the extensions from the harness I took out. I'm also going to wrap the area by the EGR with an additional layer of high temp tape before I weave it back through the intake manifold.
Have you guys had the M90 serviced/rebuilt? Mine was pretty loud and had slop in the snout bearing. The guy who rebuilt it said it only had minimal wear, which is good.

 

[Aliveiride]

^1

Yep, extend the TPS/IAC wires - much easier than ripping into the harness. Of course that presumes you can splice extension wires reliably (either you are really good at soldering or you have a good crimper). Use heatshrink tubing with the internal adhesive liner to get a nice water proof cover over the solder/crimp area.

The short bypass hose is a pain in the arse and yes, it does not line up exactly. Great mold design... (not). The ones I've done weren't too far off, but they certainly weren't perfect. Maybe a piece of silicone hose would work better (more pliable).

Here's my install writeup from many years ago, might help you -> Kazuma Supercharger Install

cheers,
george.

Finally got the SC and throttle body reassembled, what a pain. I now see how the original installer stripped out one of the tapped holes in the SC housing that accepts the throttle body adapter bolts, they are next to impossible to line up with the bypass hose installed with that misalignment between the nipples. Luckily I was able to drill out the stripped hole and install an insert. Whoever stripped it originally just gave up and put FIPG all over the head of the bolt to hold it in. I was able to somewhat fix the misalignment issue by removing the bypass elbow from the Kazuma piece and machining a spacer that moved it out an 1/8" to match the throttle body adapter nipple but there was nothing I could do about the vertical misalignment. I swapped to a silicone hose which helped but it took some serious convincing to get all 4 throttle body adapter bolts started.
I opted against enlarging the holes in the Kazuma piece for fear of affecting the pulley/belt alignment and now everything looks good.

Next step is extending the wires and adding an additional layer of heat shielding to the harness. I was able to get enough non-heat affected wire out of the old harness to make a 9" extension which should be more than enough. I got some high temp rated, adhesive lined, shrink tubing as well to seal my solder joints.

 

[Aliveiride]