Secondary air injection system P2440 and P2442

So I recall your pump died real early (like ~8K miles). In your case was it the filter that made it fail? Or was it just a defective pump?

 

My understanding is a big part of the problem is moisture getting into the valves through the air-pump and causing them to stick. That's the reason for the pump to run after shutdown on the 2013 and up. To purge the system of moisture. When they stick open hot exhaust gases are allowed to back up into the pump burning it up. I would think if you removed the foam filter even more moisture would be allowed to inter the system. Possibly causing failure even sooner.

 

Now that our 2012 Taco's are coming up on the 5 year warranty, has anyone gone out and purchased additional years / miles from either a 3rd party or Toyota?

 

If you do this be darn sure to read the fine print. I know in one of the threads related to this problem someone in Canada discovered that the Toyota extended warranty he purchased specifically did not cover the pump or valves. The way the warranties are often written instead of listing things they do not cover they specifically list systems they do cover and anything they don't list is not covered. This pump and valve fell into the category of things not listed and he got screwed.

 

Sort of the opposite really, as I understand it the source of the moisture is from the exhaust itself (remember exhaust is mostly H20 and CO2 if the engine is working properly). The pump running after shutdown is to purge the moist exhaust gasses with fresh air from the outside. In other words the air on the outside of the filter is the good stuff and the air on the inside of the filter is what you are trying to get out of there on shutdown.

 

Interesting...

 

And hopefully even correct! But this is TW so I'm sure if I've gotten wrong someone will be along to correct me soon!

 

I would agree that both make sense. I have been told that Toyota has redesigned the intake for the air-pump on the replacement model. To reduce the amount of moisture being taken in.

 

So if we have moisture coming in through the exhaust causing the valves to fail. And the filter on the pump is deteriorating causing the pump to fail........ We then have a $2,000 attack from 2 different directions on this system??

 

I didn't inspect it because I knew Toyota was going to fix it. Most likely the pump itself failed because before I got the light, I heard the pump make a loud squealing sound.

 

Sounds like a plan. I think that is what I'll do -- keep the foam filter if I need to swap it out for warranty issues but otherwise run the replacement.

 

Keep the front piece as well as the filter will replace this.

 

Has anyone that had the dealer fix this under warranty, still encountering problems? Just purchased a 2012 with 81k and got the extended warranty but now I'm worried I will get stranded somewhere

 

modify your filter and keep your engine bay clean

 

If the moisture that is deteriorating the valves causing them the fail is coming from the the exhaust.
How will replacing or modifying the filter stop the valves from failing?

 

Filter replacement does nothing to protect the valves. They will still fail from moisture even if you change the filter out.

Separate problem is the OEM filter degrades and falls apart with pieces being ingested into the pump vanes breaking the pump. So a different failure mode entirely from the moisture problem. More than one 2013+ owner have had valves that were fine because of the ECU change that purges on shutdown but still threw a code when the pump failed because the OEM filter fell apart.

 

If the 2013 software update purging the system of moisture stops or reduces the valves from failing.

Then the question is.......Why do we have a 3-4 year old filter media failing?

I ask anyone to answer this question.
Have you ever seen or experienced in any type of air / dry media filter fail in 36-48 months in any application other than this?
Any Lawn equipment air filters? Automotive air intake? 4 Wheeler's or Motor cycles? What about farm or industrial equipment?
Has anyone seen any air intake filters fail? One's without any outside contributing factor........
Because 6 years as an Army Diesel mechanic. Plus 30 years as a Manager and a Lead Technician of $35+ million in German industrial equipment I sure haven't.
Sure I've seen em fail or should I say collapse because of contamination or not being changed when needed. But a filter that is 36-48 months old and only runs 1-2 minutes during a cold start.....How contaminated could it get??

If we do have this.....Then Toyota surely does have it's head up it's ass.

 

I don't know why the filter fails. Could be one bad batch and most are fine? Hard to say. What I can say is the filter is just a block of open cell foam with absolutely no supporting material. So it isn't like a paper or fiber filter. I've seen thin sheet open cell foam filters in computer equipment but that is a way friendlier environment than an engine compartment. Those computer filters in an actual commercial product also are usually trapped in a metal mesh which provides mechanical support and would prevent parts from falling off.

For reference here is a picture of the filter block:

 

Got my valves and Air pump replaced yesterday. Thank goodness the parts finally came in. I was getting tired of unhooking the battery every morning to clear the Limp mode out. And my many thanks to my local Toyota dealership for getting this $1800 repair done under a "Goodwill" warranty. I still don't understand why this is not covered under the emission's warranty. Being it is 100% emissions related.

 

Nice. We may be the lucky ones. Maybe its a NC thing!?!