Toyota Tundra 2005 Setup guide

IN0KN−01
N17080
Filler Cap
Float
Reservoir
Grommet
Clip
Slotted Spring Pin
: Specified torque
Non−reusable part
Cylinder
Piston Push Rod
Washer
Snap Ring
Boot
Gasket
Lock Nut
Clevis Pin
Clevis
N·m (kgf·cm, ft·lbf)
12 (120, 9)
15 (155, 11)
−INTRODUCTION HOW TO USE THIS MANUAL IN−1
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you
in finding your way through the manual, the section title and major heading are given at the top of every page.
2. PRECAUTION
At the beginning of each section, a PRECAUTION that pertains to all repair operations contained in that sec-
tion is given.
Read these precautions before starting any repair task.
3. TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the
cause. The fundamentals of how to proceed with troubleshooting are described on page IN−19.
Be sure to read this before performing troubleshooting.
4. PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-
cial Service Materials) which should be prepared before beginning the operation and explains the purpose
of each one.
5. REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:

Illustration:
what to do and where to do
21. CHECK PISTON STROKE OF OVERDRIVE BRAKE
(a)
Task heading : what to do
SST 09350−30020 (09350−06120)
Set part No. Component part No.
Detailed text : how to do task
(b)
Piston stroke: 1.40 1.70 mm (0.0551  0.0669 in.)
Specification
Place SST and a dial indicator onto the overdrive brake pis-
ton as shown in the illustration.
Measure the stroke applying and releasing the compressed
air (392  785 kPa, 4  8 kgf/cm2or 57 114 psi) as shown
in the illustration.
IN−2 −INTRODUCTION HOW TO USE THIS MANUAL
The procedures are presented in a step−by−step format:
The illustration shows what to do and where to do.
The task heading tells what to do.
The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
This format provides the experienced technician with a FAST TRACK to the information needed. The upper
case task heading can be read at a glance when necessary, and the text below it provides detailed informa-
tion. Important specifications and warnings always stand out in bold type.
6. REFERENCES
References have been kept to a minimum. However, when they are required, you are given the page to refer
to.
7. SPECIFICATIONS
Specifications are presented in bold type throughout the text where needed. You never have to leave the
procedure to look up your specifications. They are also found in Service Specifications section for quick ref-
erence.
8. CAUTIONS, NOTICES, HINTS:
CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other
people.
NOTICES are also presented in bold type, and indicate the possibility of damage to the components
being repaired.
HINTS are separated from the text but do not appear in bold. They provide additional information to
help you perform the repair efficiently.
9. SI UNIT
The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of
Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)

IN01P−08
B02417
A
B
B17832
A
A
1GR−FE Engine
2UZ−FE Engine
−INTRODUCTION IDENTIFICATION INFORMATION IN−3
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION AND
ENGINE SERIAL NUMBER
1. VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped on the vehicle
identification number plate and certification label.
A: Vehicle Identification Number Plate
B: Certification Label
2. ENGINE SERIAL NUMBER
The engine serial number is stamped on the engine block, as
shown in the illustration.
A: Engine Serial Number

IN0CO−32
FI1066
Z11554
Seal Lock Adhesive
IN−4 −INTRODUCTION REPAIR INSTRUCTIONS
REPAIR INSTRUCTIONS
GENERAL INFORMATION
BASIC REPAIR HINT
(a) Prevent damage and maintain vehicle cleanliness by pro-
tective covering on the fender, seat and floor.
(b) During disassembly, line up parts in the order they were
removed to facilitate reassembly.
(c) Installation and removal of battery terminal:
NOTICE:
When connecting the negative (−) terminal make sure that
the steering wheel is centered.
(1) Before performing electrical work, disconnect the
negative (−) terminal cable from the battery.
(2) If it is necessary to disconnect the battery for in-
spection or repair, first disconnect the negative (−)
terminal cable.
(3) To prevent damage to the battery terminal when dis-
connecting the terminal cable, loosen the cable nut
and raise the cable straight up. Do not twist or pry
the cable off.
(4) Clean the battery terminals and cable ends with a
clean shop rag. Do not scrape them with a file or oth-
er abrasive objects.
(5) Install the cable ends to the battery terminals after
loosening the nut, and tighten the nut after installa-
tion. Do not use a hammer to tap the cable ends
onto the terminals.
(6) Be sure the cover for the positive (+) terminal is
properly in place.
(d) Check hose and wiring connectors to make sure that they
are connected securely and correctly.
(e) Non−reusable parts:
(1) Always replace cotter pins, gaskets, O−rings, oil
seals, etc. with new ones.
(2) Non−reusable parts are indicated in component il-
lustrations by the ”” symbols.
(f) Precoated parts
Precoated parts are bolts, nuts, etc. that are coated with
a seal lock adhesive at the factory.
(1) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(2) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
new seal lock adhesive to the bolt, nut or threads.

BE1367
Medium Current Fuse and High Current Fuse
Equal Amperage Rating
V00076
AbbreviationPart NameSymbolIllustration
FUSE
MEDIUM CURRENT FUSE
HIGH CURRENT FUSE
FUSIBLE LINK
CIRCUIT BREAKER
FUSE
M−FUSE
H−FUSE
FL
CB
−INTRODUCTION REPAIR INSTRUCTIONS IN−5
(3) Precoated parts are indicated in component illustra-
tions by the ”” symbols.
(g) When necessary, use a sealer on gaskets to prevent
leaks.
(h) Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
(i) Use of special service tools (SST) and special service ma-
terials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where speci-
fied and follow the proper work procedure. A list of SST
and SSM can be found in the Preparation section in this
manual.
(j) When replacing fuses, be sure the new fuse has the cor-
rect amperage rating. DO NOT exceed the rating or use
one with a lower rating.

IN0253
WRONG CORRECT
IN0252
WRONG CORRECT
IN−6 −INTRODUCTION REPAIR INSTRUCTIONS
(k) Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the prop-
er locations (see page IN−8).
Release the parking brake on a level surface and
shift to the N position.
When jacking up the front wheels of the vehicle, first
place chocks behind the rear wheels.
When jacking up the rear wheels of the vehicle,
place chocks in front of the front wheels.
When jacking up only the front or rear wheels, set
rigid racks and place chocks on front and behind the
wheels in contact with the ground.
After the vehicle is jacked up, be sure to support it
on rigid racks. It is extremely dangerous to do any
work on a vehicle raised on a jack alone, even for
a job that can be finished quickly.
(l) Observe the following precautions to avoid damage to the
following parts:
(1) Do not open the cover or case of the ECU unless
absolutely necessary. (Static electricity transmitted
through human touch may destroy the IC.)
(2) To disconnect vacuum hoses, pull off the end of the
hose, not the middle.
(3) To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
(4) Be careful not to drop electrical components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused.
(5) When steam cleaning an engine, protect the elec-
tronic components, air filter and emission−related
components from water.
(6) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(7) When checking continuity at the wire connector, in-
sert the tester probe carefully to prevent terminals
from bending.
(8) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step−down
adapter for adjustment. Once the hose has been
stretched, it may leak air.

IN0002
Example
−INTRODUCTION REPAIR INSTRUCTIONS IN−7
(m) Installation and removal of vacuum hose:
(1) When disconnecting vacuum hoses, use tags to
identify where they should be reconnected to.
(2) After completing a job, double check that the vacu-
um hoses are properly connected. A label under the
hood shows the proper layout.
(n) Unless otherwise stated, all resistance should be mea-
sured at an ambient temperature of 20°C (68°F). Mea-
surement should be made after the engine has cooled
down. If measured at high temperatures immediately af-
ter the vehicle has been running, resistance may be out-
side specifications.

IN0DY−05
B07972
JACK POSITION                  
Front          Center of crossmember
Rear          Center of rear axle housing
SUPPORT POSITION
Safety stand                
Front
IN−8 −INTRODUCTION REPAIR INSTRUCTIONS
VEHICLE LIFT AND SUPPORT LOCATIONS

IN0KM−01
BO4111
Negative Cable
−INTRODUCTION FOR ALL OF VEHICLES IN−9
FOR ALL OF VEHICLES
PRECAUTION
1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND
SEAT BELT PRETENSIONER
(a) The TOYOTA TUNDRA is equipped with an SRS (Sup-
plemental Restraint System), such as the driver airbag,
front passenger airbag assembly and seat belt preten-
sioner.
Failure to carry out service operations in the correct se-
quence could cause the supplemental restraint system to
unexpectedly deploy during servicing, possibly leading to
a serious accident.
Further, if a mistake is made in servicing the supplemental
restraint system, it is possible the SRS may fail to operate
when required. Before servicing (including removal or
installation of parts, inspection or replacement), be sure
to read the following items carefully, then follow the cor-
rect procedure described in this manual.
(b) GENERAL NOTICE
(1) Malfunction symptoms of the supplemental re-
straint system are difficult to confirm, so the diag-
nostic trouble codes become the most important
source of information when troubleshooting. When
troubleshooting the SRS, always check the diag-
nostic trouble codes before disconnecting the bat-
tery (see page DI−1810).
(2) Work must be started after 90 seconds from the
time the ignition switch is turned to the LOCK posi-
tion and the negative (−) terminal cable is discon-
nected from the battery.
(The supplemental restraint system is equipped
with a back−up power source because if work is
started within 90 seconds of disconnecting the neg-
ative (−) terminal cable from the battery, the SRS
may deploy.)
When the negative (−) terminal cable is discon-
nected from the battery, memory of the clock and
audio systems will be cancelled. So before starting
work, make a record of the contents memorized in
each memory system. When work is finished, reset
the clock and audio systems as before.
To avoid erasing the memory of each memory sys-
tem, never use a back−up power supply from anoth-
er battery.

F04784
Mark
IN−10 −INTRODUCTION FOR ALL OF VEHICLES
(3) Even in case of a minor collision where the SRS
does not deploy, the steering wheel pad (see page
RS−24), front passenger airbag assembly (see
page RS−38), side airbag assembly (see page
RS−77, RS−52 or RS−67) curtain shield airbag as-
sembly (see page RS−85) and seat belt pretension-
er (see page BO−241) should be inspected.
(4) Never use SRS parts from another vehicle. When
replacing parts, replace them with new ones.
(5) Before repairs, remove the airbag sensor if shocks
are likely to be applied to the sensor during repairs.
(6) Never disassemble or repair the airbag sensor as-
sembly, steering wheel pad, front passenger airbag
assembly or seat belt pretensioner.
(7) If the airbag sensor assembly, steering wheel pad,
front passenger airbag assembly or seat belt pre-
tensioner has been dropped, or if there are cracks,
dents or other defects in the case, bracket or con-
nector, replace them with new ones.
(8) Do not directly expose the airbag sensor assembly,
steering wheel pad, front passenger airbag assem-
bly or seat belt pretensioner to hot air or flames.
(9) Use a voltmeter/ohmmeter with high impedance (10
kΩ/V minimum) for troubleshooting of the electrical
circuit.
(10) Information labels are attached to the periphery of
the SRS components. Follow the instructions on the
labels.
(11) After work on the supplemental restraint system is
completed, check the SRS warning light (see page
DI−1855).
(c) SPIRAL CABLE (in Combination Switch)
The steering wheel must be fitted correctly to the steering
column with the spiral cable at the neutral position, other-
wise cable disconnection and other troubles may result.
Refer to SR−28 or SR−42 concerning correct steering
wheel installation.

F14450 B13595
Example:
CORRECT WRONG
Z13950
Example:
−INTRODUCTION FOR ALL OF VEHICLES IN−11
(d) STEERING WHEEL PAD (with Airbag)
(1) When removing the steering wheel pad or handling
a new steering wheel pad, it should be placed with
the pad top surface facing up.
Storing the pad with its metallic surface upward may
lead to a serious accident if the airbag inflates for
some reason. In addition, do not store a steering
wheel pad on top of another one.
(2) Never measure the resistance of the airbag squib.
This may cause the airbag to deploy, which could
cause serious injury.
(3) Grease or detergents of any kind should not be ap-
plied to the steering wheel pad.
(4) Store the steering wheel pad where the ambient
temperature remains below 93°C (200°F), with low
humidity and away from electrical noise.
(5) Before using an electric welder, first disconnect the
airbag connector (the connector is yellow and has
4 pins) under the steering column near the com-
bination switch connector.
(6) As a safety measure, always deploy airbags using
an SST before disposal (see page RS−25).
Deploy airbags in a safe place away from electrical
noise.

B12629
Example:
Correct Wrong
Z13951
Example:
IN−12 −INTRODUCTION FOR ALL OF VEHICLES
(e) FRONT PASSENGER AIRBAG ASSEMBLY
(1) Always store a removed or new front passenger air-
bag assembly with the airbag deployment side fac-
ing up.
Storing the airbag assembly with the airbag deploy-
ment side facing down could cause a serious acci-
dent if the airbag inflates.
(2) Never measure the resistance of the airbag squib.
This may cause the airbag to deploy, which could
cause serious injury.
(3) Grease or detergents of any kind should not be ap-
plied to the steering wheel pad.
(4) Store the steering wheel pad where the ambient
temperature remains below 93°C (200°F), with low
humidity and away from electrical noise.
(5) Before using an electric welder, first disconnect the
airbag connector (the connector is yellow and has
4 pins) under the steering column near the com-
bination switch connector.
(6) As a safety measure, always deploy airbags using
an SST before disposal (see page RS−39).
Deploy airbags in a safe place away from electrical
noise.

B02121
Example:
−INTRODUCTION FOR ALL OF VEHICLES IN−13
(f) SEAT BELT PRETENSIONER
(1) Never measure the resistance of the seat belt pre-
tensioner. This may cause the seat belt pretension-
er to activate, which could cause serious injury.
(2) Never disassemble the seat belt pretensioner.
(3) Never install the seat belt pretensioner in another
vehicle.
(4) Store the seat belt pretensioner where the ambient
temperature remains below 80°C (176°F), with low
humidity and away from electrical noise.
(5) Before using an electric welder, first disconnect the
connector (the connector is yellow and has 2 pins).
(6) As a safety measure, always activate the seat belt
pretensioner before disposal (see page BO−245).
Activate the pretensioner in a safe place away from
electrical noise.
(7) The seat belt pretensioner becomes hot after ac-
tivation. Allow it to cool before disposing. Never use
water to cool the seat belt pretensioner.

B02129
Example: Correct Wrong
B01546
Example:
IN−14 −INTRODUCTION FOR ALL OF VEHICLES
(g) SIDE AIRBAG ASSEMBLY
(1) Always store a removed or new side airbag assem-
bly with the airbag deployment side facing up.
Storing the airbag assembly with the airbag deploy-
ment side facing down could cause a serious acci-
dent if the airbag inflates.
(2) Never measure the resistance of the airbag squib
(This may cause the airbag to deploy, which is very
dangerous.).
(3) Grease should not be attached to the side airbag
assembly and the surface should not be cleaned
with any kind of detergents.
(4) Store the airbag assembly where the ambient tem-
perature remains below 93°C (200°F), without high
humidity and away from electrical noise.
(5) When using electric welding, first disconnect the air-
bag connector (yellow color and 2 pins) under the
seat before starting work.
(6) When disposing of a vehicle or the side airbag as-
sembly alone, the airbag should be deployed using
an SST before disposal (See page RS−78,
RS−53 or RS−68).
Perform the operation in a safe place away from
electrical noise.

H11622 H12060 B08604
Example: Correct Wrong
Clear Plastic Bag
R06952H12059 B08605
Example:
−INTRODUCTION FOR ALL OF VEHICLES IN−15
(h) CURTAIN SHIELD AIRBAG ASSEMBLY
(1) Always store a removed or new curtain shield air-
bag assembly in a clear plastic bag, and keep it in
a safe place.
NOTICE:
Protection bag is not reused.
CAUTION:
Never disassemble the curtain shield airbag assembly
(2) Never measure the resistance of the airbag squib
(This may cause the airbag to deploy, which is very
dangerous.).
(3) Grease should not be attached to the curtain shield
airbag assembly and the surface should not be
cleaned with any kind of detergents.
(4) Store the airbag assembly where the ambient tem-
perature remains below 93°C (200°F), without high
humidity and away from electrical noise.
(5) When using electric welding, first disconnect the air-
bag connector (yellow color and 2 pins) into the
instrument panel before starting work.
(6) When disposing of a vehicle or the curtain shield air-
bag assembly alone, the airbag should be deployed
using an SST before disposal (See page RS−86).
Perform the operation in a safe place away from
electrical noise.

IN−16 −INTRODUCTION FOR ALL OF VEHICLES
(i) AIRBAG SENSOR ASSEMBLY
(1) If an airbag sensor assembly has been involved in
a collision where its SRS has deployed, do not re-
use it.
(2) The connectors to the airbag sensor assembly
should be connected or disconnected with the sen-
sor mounted on the floor. Failure to do so could
cause undesired deployment of the SRS.
(3) To avoid serious injury, servicing the SRS must be
started 90 seconds after:
The ignition switch is turned to the LOCK
position.
The negative (−) terminal cable is discon-
nected from the battery.
Even if only loosening the set bolts of the airbag
sensor assembly, you must follow the above guide-
lines.
(j) WIRE HARNESS AND CONNECTOR
The SRS wire harness is integrated with the instrument
panel wire harness assembly. All the connectors in the
system are a standard yellow color. If the SRS wire har-
ness becomes disconnected or the connector becomes
broken, etc., repair or replace it as shown on page
RS−139.

−INTRODUCTION FOR ALL OF VEHICLES IN−17
2. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER
CAUTION:
If large amounts of unburned gasoline flow into the converter, it may overheat and create a fire haz-
ard. To prevent this, observe the following precautions and explain them to your customer.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid idling the engine for more than 20 minutes.
(c) Avoid spark jump test.
(1) Perform spark jump tests only when absolutely necessary. Perform this test as rapidly as pos-
sible.
(2) While testing, never race the engine.
(d) Avoid prolonged engine compression measurement.
Engine compression tests must be done as rapidly as possible.
(e) Do not run engine when the fuel tank is nearly empty.
This may cause the engine to misfire and create an extra load on the converter.
(f) Avoid coasting with ignition turned off.
(g) Do not dispose of used catalyst with gasoline or oil contaminated parts.
3. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM
For vehicles with mobile communication systems such as two−way radios and cellular telephones, observe
the following precautions.
(1) Install the antenna as far away as possible from the ECU and sensors of the vehicle’s electronic
system.
(2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the ve-
hicle’s electronic systems. For details about ECU and sensor locations, refer to the applicable
component’s section.
(3) Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid
running the antenna feeder parallel with other wire harnesses.
(4) Check that the antenna and feeder are correctly adjusted.
(5) Do not install powerful mobile communications system.
4. FOR USING OBD II SCAN TOOL OR HAND−HELD TESTER
CAUTION:
Observe the following items for safety reasons:
Before using the hand−held tester or OBD II scan tool, the hand−held tester’s operator manual
or OBD II scan tool’s instruction book should be read thoroughly.
Be sure to route all cables securely when driving with the hand−held tester or OBD II scan tool
connected to the vehicle. (I.e. keep cables away from feet, pedals, steering wheel and shift le-
ver.)
Two persons are required when test−driving with the hand−held tester or OBD II scan tool: one
person to drive the vehicle and another to operate the hand−held tester or OBD II scan tool.