Operation CHARM: Car repair manuals for everyone.
Home >> Toyota >> 2007 >> Tundra 2WD V8-5.7L (3UR-FE) >> Repair and Diagnosis >> Powertrain Management >> Emission Control Systems >> Air Injection >> Air Injection Control Valve >> Service and Repair
Manuals through 2025 now available!

Our trusted friends have launched a new website named LEMON, which has newer manuals. It also contains all the CHARM manuals.

LEMON is the spiritual successor to CHARM, I recommend you try it!

Link: lemon-manuals.la or lemon-manuals.org.ua

(Some people have issue connecting. LEMON is investigating. For now, use Firefox or change your DNS server)

Or, hide this message: temporarily or permanently

Air Injection Control Valve: Service and Repair

REMOVAL

1. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY
a. Remove the exhaust manifold.

2. REMOVE INTAKE MANIFOLD
a. Remove the intake manifold.

3. DISCONNECT NO. 1 WATER BY-PASS HOSE




a. Disconnect the No. 1 water by-pass hose from the water by-pass joint and water inlet housing.

4. DISCONNECT NO. 2 WATER BY-PASS HOSE
a. Disconnect the No. 2 water by-pass hose from the water by-pass joint.

5. DISCONNECT NO. 2 WATER BY-PASS PIPE SUBASSEMBLY




a. Remove the 3 bolts and disconnect the No. 2 water by-pass pipe.




6. REMOVE NO. 2 ENGINE COVER
7. DISCONNECT FUEL TUBE CLAMP




a. Disconnect the fuel tube clamp from the bracket.

8. REMOVE NO. 1 ENGINE COVER

9. REMOVE FRONT WATER BY-PASS JOINT




a. Disconnect the engine coolant temperature sensor connector.




b. Remove the 4 nuts, front water by-pass joint and 2 gaskets.

10. REMOVE AIR TUBE




a. Disconnect the No. 2 and No. 3 hoses.
b. Disconnect the air pump's connector.
c. Disconnect the air pump connector clamp's holder.
d. Using a clip remover, detach the wire harness claw.




e. Remove the 2 bolts and air tube.
f. Disconnect the 2 No. 1 air hoses from the air tube.

11. REMOVE AIR SWITCHING VALVE ASSEMBLY




a. Disconnect the knock sensor's connector.
b. Remove the bolt and bracket.
c. Disconnect the 2 air switching valve connectors.




d. Remove the 3 bolts and air switching valve.

12. REMOVE NO. 2 AIR TUBE




a. Remove the 2 bolts, No. 2 air tube and gasket.

NOTE: Be careful not to damage the installation surface of the gaskets.

13. REMOVE NO. 3 AIR TUBE




a. Remove the 2 bolts, No. 3 air tube and gasket.

NOTE: Be careful not to damage the installation surface of the gaskets.

INSTALLATION

1. INSTALL NO. 3 AIR TUBE




a. Install a new gasket and the No. 3 air tube with the 2 bolts.

Torque: 10 N.m (102 kgf. cm, 7 ft.lbf)

NOTE: Make sure the gasket's claws are not caught between the air tube and air switching valve.

HINT: The identification color on the flange is orange.

2. INSTALL NO. 2 AIR TUBE




a. Install a new gasket and the No. 2 air tube with the 2 bolts.

Torque: 10 N.m (102 kgf. cm, 7 ft.lbf)

NOTE: Make sure the gasket's claws are not caught between the air tube and air switching valve.

HINT: The identification color on the flange is blue.

3. INSTALL AIR SWITCHING VALVE ASSEMBLY




a. Install the air switching valve with the 3 bolts.

Torque: 21 N.m (214 kgf. cm, 15 ft.lbf)

b. Connect the 2 air switching valve connectors.




c. Install the bracket with the bolt.

Torque: 8.0 N.m (82 kgf. cm, 71 in.lbf)

d. Connect the knock sensor's connector.

4. INSTALL AIR TUBE
a. Connect the 2 No. 1 air hoses to the air tube.




b. Connect the air tube to the air switching valve, and install the air tube with the 2 bolts.

Torque: 10 N.m (102 kgf. cm, 7 ft.lbf)

c. Connect the air pump connector clamp's holder.
d. Attach the wire harness claw.
e. Connect the air pump's connector.




f. Connect the No. 2 and No. 3 hose.

5. INSTALL FRONT WATER BY-PASS JOINT




a. Install 2 new gaskets and the front water by-pass joint with the 4 nuts.

Torque: 21 N.m (214 kgf. cm, 15 ft.lbf)

b. Connect the engine coolant temperature sensor connector.

6. CONNECT NO. 2 WATER BY-PASS PIPE SUBASSEMBLY




a. Connect the No. 2 water by-pass pipe with the 3 bolts.

Torque: 10 N.m (102 kgf. cm, 7 ft.lbf)

7. CONNECT NO. 2 WATER BY-PASS HOSE




a. Connect the No. 2 water by-pass hose to the water by-pass joint.

8. CONNECT NO. 1 WATER BY-PASS HOSE
a. Connect the No. 1 water by-pass hose to the water by-pass joint and water inlet housing.

9. INSTALL NO. 1 ENGINE COVER






NOTE: Make sure that the No. 1 engine cover is level with the top surface of the intake port of the cylinder head for 1 and 2.

HINT:
- Align the No. 1 engine cover cutouts with the air tube.
- Align the No. 1 engine cover with the air switching valve surface and cylinder head wall.

10. CONNECT FUEL TUBE CLAMP




a. Connect the fuel tube clamp to the bracket.

11. INSTALL NO. 2 ENGINE COVER






NOTE: Make sure that the No. 2 engine cover is level with the top surface of the intake port if the cylinder head.

HINT:
- Align the No. 2 engine cover cutout with the air tube.
- Align the No. 2 engine cover with the front water bypass joint and cylinder head wall.

12. INSTALL INTAKE MANIFOLD
a. Install the intake manifold.

13. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY
a. Install the exhaust manifold.
pro multis · About Operation CHARM