Some 2007 through 2010 Tundra owners are being asked to replace the main components of their truck's Air Injection System, with costs in excess of $4,000.
Because of a design flaw, water can enter the truck's air injection system and destroy 2 small air induction pumps ($1100 each) as well as 2 emissions valves ($500 each). With labor, the total cost exceed $4,000.
Toyota is aware of this problem and has issued multiple TSB's. However, because this system is failing after the 3 year / 36k mile warranty ends, Toyota is not fixing this repair under warranty.
The air injection system is an emissions component designed to reduce cold-start emissions. It is not necessary for the core function of the truck, and is only needed for 1 or 2 minutes at vehicle start. Yet the failure of this system puts the Tundra into "limp mode," resulting in substantially less power until the check engine code is cleared.
While it's not clear HOW water is entering the air injection system, the number of owners with this problem suggests this is a design flaw. Toyota has issued a TSB for all 2007 Tundras, as well as many 2008 and 2010 models, which would seem to support this conclusion.
Many Tundra owners who are faced with this repair fail to understand why this system was designed so poorly as to ingest water, as well as the incredible cost of the two electric air pumps ($900-$1200 each, depending on dealer mark-up). What's more, Tundra owners wonder why failure of this non-essential system puts the truck into "limp mode."
Read the full details on TundraHeadquarters.com