K&N 77 series User manual

KLN

OQP

ZYX

77-9034KP

TOOLS NEEDED:

PARTS LIST:

Description Qty. Part # Description Qty. Part # Description Qty. Part #

NOTE: This kit was not designed

to t vehicles with a body lift.

1. Turn o󰀨 the ignition and disconnect the negative

battery cable.

NOTE: Disconnecting the negative battery cable

erases pre-programmed electronic memories.

Write down all memory settings before

disconnecting the negative battery cable. Some

radios will require an anti-theft code to be

entered after the battery is reconnected. The

anti-theft code is typically supplied with your

owner’s manual. In the event your vehicles’

anti-theft code cannot be recovered, contact an

authorized dealership to obtain your vehicles

anti-theft code.

TO START:

2. Lift up the engine cover to dislodge it from the

mounting grommets and then remove the cover

from the vehicle.

TOYOTA

2010-14 FJ Cruiser

2010-18 4Runner

V6-4.0L

Ratchet

Extension

13mm socket

12mm socket

10mm socket

10mm wrench

Wrench

3mm allen wrench

Pliers

Flat blade screw driver

3. Disconnect the mass air sensor electrical

connection and then unhook the wiring harness

from the air box.

NOTE: The wiring harness attaches in three

locations.

4. Unhook the fuel pressure vent line from the fuel

pressure regulator.

5. Disconnect the crank case vent hose from the

stock intake tube.

6. Remove the bolt which secures the tube

mounting bracket to the engine valve cover.

A HOSE CLAMP #48 1 08601

B HOSE: 3.25”ID TO 3.50 ID 1 084091

C HOSE CLAMP #56 3 08620

D HOSE; 4MM ID X 18” L 1 08153

E VENT; STRT, 3/16 1 080021

F VENT; STRT, 5/8 BARBED 1 08911

G BOLT; M4-0.07 8MM, A/H 2 07733

HINTAKE TUBE 1 27472

I HOSE; 3-1/2”ID X 3”L 1 084057

J STUD; M/M 8MM X 1.25 4 070227

K BRACKET “L” 1 070712

L WASHER; 8MM, FLAT, SS 4 08272

M NUT; 6MM NYLOCK, HEX 2 07512

N NUT; 8MM NYLOCK, SS 4 07502

O WASHER; 1/4”ID X 5/8”OD 13 08275

P BOLT; M6X1.00X16MM ,SS 8 07730

Q WASHER; 1/4” LOCK, ZN 9 08198

R HEAT SHIELD 1 074067-1

S BOLT; 6MM-1.00X16MM, SS 3 07812

T HEAT SHIELD LID 1 074068

UEDGE TRIM (30”) 1 102489

V BRACKET “L” 1 08022

W STUD; M6 X 1, 1” T 1 02033

X ADAPTER; 6” FILTER 3.5” 1 21512-1

Y HOSE CLAMP #104 1 08697

Z AIR FILTER 1 RF-1048

NOTE: FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS AND NOT USING THE PROVIDED HARDWARE

MAY DAMAGE THE INTAKE TUBE, THROTTLE BODY AND ENGINE.

If you need any assistance please call 1-800-858-3333 to speak with a representative

in our Customer Service Center before returning the product.

INSTALLATION INSTRUCTIONS

Continued

10. Remove the rear P/S reservoir mounting bolt

shown.

13. Install the 6mm rubber mounted stud into the

inner fender location shown.

NOTE: On some models, a horn may be

attached in this location.

14. Install the lter adapter into the heat shield and

secure with the provided hardware.

15. Install the provided mounting bracket (070712)

onto the heat shield and secure with the provided

hardware.

16. Install the provided mounting bracket (08022)

onto the heat shield and secure with the provided

hardware.

17. Cut the provided edge trim into two lengths as

shown. One section is to be 10.5” long and one

section is to be 19” long.

18. Install the 10.5” long piece onto the heat shield

as shown.

19. Set the heat shield onto the rubber mounted

studs and the secure with the provided hardware.

NOTE: On models that had a horn attached

in this location, be sure to reattach the horn

between the heat shield bracket and rubber

mounted stud.

20. Install the provided silicone hump hose

(084057) onto the lter adapter and secure with the

provided hose clamp.

21. Install the provided silicone step hose (084091)

onto the throttle body and secure with the provided

hose clamp.

22. Remove the screws which secure the mass air

sensor to the factory air box and then remove the

mass air sensor from the air box.

11. On models with the Air injection pump located

in front of the air box next to the Power steering

reservoir, remove the three bolts securing the

pump to the inner fender.

11a. Lift up the air injection pump, disconnect the

electrical connection and then set the air injection

pump over to side.

12. Install the four rubber mounted studs into the

factory air box and P/S reservoir as shown.

NOTE: The forward most rubber mounted stud

is only used if the vehicle is equipped with the

air injection pump located in front of the factory

air box.

19a. Install the air injection pump onto the heat

shield and forward rubber mounted stud and then

secure with the provided hardware. Reconnect the

air injection pump electrical connection.

9. Loosen and remove the three bolts securing the

lower air box and then remove the lower air box

from the vehicle.

NOTE: K&N Engineering, Inc., recommends that

customers do not discard factory air intake.

7. Loosen the hose clamp which secures the intake

tube to the throttle body.

8. Release the four clips which secure the upper air

box to the lower air box and then remove the intake

tube and upper air box from the vehicle.

INSTALLATION INSTRUCTIONS

Continued

1. Start the engine with the transmission in neutral

or park, and the parking brake engaged. Listen

for air leaks or odd noises. For air leaks secure

hoses and connections. For odd noises, find cause

and repair before proceeding. This kit will function

identically to the factory system except for being

louder and much more responsive.

2. Test drive the vehicle. Listen for odd noises or

rattles and x as necessary.

3. If road test is ne, you can now enjoy the added

power and performance from your kit.

4. K&N Engineering, Inc., requires cleaning the

intake system’s air lter element every 100,000

miles. When used in dusty or o󰀨-road

environments, our lters will require cleaning more

often. We recommend that you visually inspect

your lter once every 25,000 miles to determine

if the screen is still visible. When the screen is no

longer visible some place on the lter element, it is

time to clean it. To clean and re-oil, purchase our

lter Recharger® service kit, part number 99-5050

or 99-5000 and follow the easy instructions.

ROAD TESTING:

36. It will be necessary for all K&N® high ow intake

systems to be checked periodically for realignment,

clearance and tightening of all connections.

Failure to follow the above instructions or proper

maintenance may void warranty.

34. Reconnect the vehicle’s negative battery cable.

Double check to make sure everything is tight and

properly positioned before starting the vehicle.

* FREE K&N® decal To register your warranty, please see us online at knlters.com/register. FREE K&N® decal *

• 1455 CITRUS ST., P.O. BOX 1329, RIVERSIDE, CA., U.S.A. 92502 • TECH SERVICE 800-858-3333 • FAX 951-826-4001

• e-mail: tech@knlters.com® • WWW: http://www.knlters.com®

35. The C.A.R.B. exemption sticker, (attached),

must be visible under the hood so that an

emissions inspector can see it when the vehicle

is required to be tested for emissions. California

requires testing every two years, other states may

vary.

28. Connect the provided fuel pressure vent line to

the fuel pressure regulator and then connect the

open end to the 3/16 vent tting in the K&N® intake

tube.

29. Install the K&N® air lter onto the lter adapter

and secure with the provided hose clamp.

NOTE: Drycharger® air lter wrap; part #

RF-1020DK is available to purchase separately.

To learn more about Drycharger® lter wraps or

look up color availability please visit

http://www.knlters.com®.

30. Install the remaining 19” piece of edge trim onto

the heat shield cover as shown.

31. Install the heat shield cover onto the heat shield

and secure with the provided hardware.

NOTE: Use of the heat shield cover is not

mandatory; it is recommended that the cover is

used during conditions of heavy moisture such

as water crossings where water can be thrown

from the engine fan.

32. Reinstall the engine cover onto the engine.

33. Reconnect the mass air sensor electrical

connection.

NOTE: Due to manufacturer tolerance, the

wiring harness pigtail for the mass air sensor

electrical connection may be tight. If the

harness is too tight, cut back the tape that

wraps the harness to free up some of the

harness. Then retape the harness for protection

leaving the extra slack.

19057M

8/09/18

27. Connect the crank case vent line to the 5/8 vent

tting and secure with the factory spring clamp.

23. Install the mass air sensor into the K&N® intake

tube and secure with the provided hardware.

24. Install the 5/8 vent tting into the K&N® intake

tube as shown.

NOTE: Plastic NPT ttings are easy to cross

thread. Install the vent tting “hand” tight, then

turn it two complete turns with a wrench.

25. Install the 3/16 vent tting into the K&N® intake

tube as shown.

26. Install the K&N® intake tube into hump hose at

the lter adapter and then into the silicone hose at

the throttle body, align the tube for proper t and

then tighten the hose clamps.

NOTE: Some models may have a larger bundled

wiring harness on the valve cover that may

contact the K&N® intake tube after assembly.

On models that the harness interferes it is

recommended that the harness be loosened

from the mounting location and repositioned

to clear the intake tube and resecure with tie

wraps available from a local auto parts store.

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