Secondary air system limp mode HELP

2014 Tacoma 4.0 auto prerunner.

Hello! I’ve been dealing with the secondary air system for a couple of months now.
I had the Hewitt bypass full kit and it didn’t help with the problem, there’s something else causing the check/trac lights to come on and limp mode the engine.
Hewitt has been very patient and helpful working with me they have sent me 3 different kits even updating the last one with the latest firmware but still having the problem intermittently.
I’m currently driving with stock components pump, valves, valve pressure sensors, module etc.
I can clear the codes once the engine get to normal driving temperature and drive the truck normally for the rest of the day. usually I get the codes limp mode in the mornings, middle of the day or if a warm day I got no issues at all.
Any advice what could be causing my problem? I just got new oem gas cap for code p1613 but nothing change. Also I have checked a good amount of the wiring harness on the truck everything is/seems in good condition.
please help.

 

That code is typically set when the power or ground circuit to the Air Injection Control Driver is open.

 

Dm93 and what could caused the circuit to open? What do I need to look/diagnose?

 

Corrosion, broken wire, blown fuse, etc.
Start with checking the AIR PMP fuse 50A in the underhood fuse box, if that's good then you need to get a test light and check at the Air Injection Control Driver connector.
On the 2 pin connector Pin 2 (White) should have power at all times, on the other connector Pin 5 (Blue/White) should have power with the key on and Pin 1 (White/Black) should be grounded at all times.

 

I agree check the fuse, also I do not have one yet but looking into HP tuner just for this reason

 

Right, pump, module/driver, pressure sensors, valves are all good and working, no fuse or relay blown, I have check the wiring harness (removed air intake completely) nothing wrong there.
The system works, as I stated before, this happens intermittently mostly mornings when temperatures are probably 60s. I live in florida.

 

Dm93 thanks for your valuable help,
I’m getting a test light today, and I’ll be doing some testing in all of those wires and connection points.
I was checking on you’re last/previous conversation with GrampasTacoma2 member, you think I should duplicate/perform the troubleshot he did as well?

 

He had a 2.7L if I remember correctly and also had multiple other codes but yes you need to test powers and grounds at the Air Injection Driver module.
Being it's an intermittent problem everything may test good when it's working, the trick is gona be catching it when it's acting up and testing things then.

 

That’s correct.
It happens almost every morning or at least when it sits for more than 10 hours with out starting the engine.
Once the engine gets it’s driving normal temperature I’m able to clear the codes on the go (while driving) and drive no problem for the rest of the day even shutting down the engine for hours nothing happens until next morning. I’ll keep you in the loop.
Thanks again.

 

So far I have tested blue/white wire on the AID connector and it shows 12v with ignition on, and neg when off. Using meter and test light.
Also checked on the same connector
Pins 1(E) and 2(DI) and white/black wire 0 voltage and green/red wire shows 11.6 v but when using the test light is very dimm.
With ignition off both checked 12.5 volts negative

 

Pin 2 Green/Red is the diagnostic monitor line to the PCM it operates with a pulsed signal so you wont see battery voltage there.

Did you check Pin 5 Blue/White with a test light and also Pin 1 White of the 2 pin connector? Those should both have battery voltage.

 

I see! yes I have checked the pin 5 B/W wire. It shows 12v with meter and very bright light using test light.
im using the reference shit as for guidance. 2 pin connector I got 12.5v and good test light.

 

How bout this white connector?

 

You said power was good at the AID, that connector is before that.
Does the air pump run at all on a cold start?

 

Yes, pump works on cold start.

 

But the code sets anytime the system runs?

 

Mostly when temperatures are below 70f
Per example no lights on Saturday truck started and drive fine, my scanner read 0 codes. I started the engine this morning around 730am temperature was at 70f according with local weather and there it was limp mode and trac/check engine lights on. 3 codes p1613

 

shows only 1 at the moment since I cleared the codes before beginning checking for posible wiring issues today.

 

Intermittents are the worst to track down, testing has to be done when the problem happens otherwise everything tests good.

Something like this ideally I'd have a 4 channel scope on it, a channel on each of the powers, 1 channel on ground, and 1 on the DI signal at the PCM when the problem is happening and see what I'm losing.

 

Well, if I can’t figure out anything myself it will have to be the dealership do a diagnostic, probably ask the tech to focus on ECM performance.