Secondary air injection system P2440 and P2442

Same here, going on a back country hunt next week and wont have power or a cell phone for 14 days. Terrible that the weakest link on my truck is a stupid pump that addresses emissions for 10 seconds at startup.

It's obvious the system is defective and it's only a matter of time before the valves fail in my 2013. I will delete them eventually. If they're not going to cover it don't gouge us on the parts, take some responsibility for Christ sake.

 

A couple weeks ago I got the P2440 and P2442 codes. I checked this forum and several others and found that TSB 0333-17 (Technical Service Bulletin) covers the part. I had my secondary injector valves replaced at no cost to me!
So if anyone is having a hard time at the dealer, just mention "TSB 0333-17", because it seemed like they didn't want me to know about it.

 

Your truck must be exhibiting the symptoms for them to fix it. Mine wasn't as I had the codes cleared by my mechanic. However, said mechanic wrote up the service note with the P codes and Toyota used that note as evidence. Fixed for free.

 

My 2012 Tundra started running terrible. Lights came on. Diagnosed as Code P2440 Secondary Air injection Switching Valve. I had just run through a lot of water that splashed under the truck. Repair estimates were $1500-$3000. It sat at the Toyota dealer for 2 days while they attempted to extend warranty due to this issue being common on this truck. (Which they would not). I went to pick up truck and it ran great. Switched off the warning lights and everything is fine now. Runs great again. I bet that many owners will get this repair done when it simply needs to dry out!

 

I got these codes on my 2012 Tacoma i'm at 192K, i honestly believe this is the first issue i have had with this truck. I did the uni filter on the air pump some time ago maybe a year or so after reading about it on here. Not wanting to go deal with the stealership, i saw on the form about the Hewitt-tech relay bypass. It says it would take an hour or so to put on....well i'm not a mechanic so it took me several hours to complete. They have blocking plates that have to be put on and they are not is easy spots to put on (keeping everything put together). NOTE - if you have the V6 the blocking plate on the left side of the air injectors, use a bit of leverage to be able to slide the block plate on. NOTE - 10mm wrench was all i could use to get the blocking plate on the right side of air injectors so it took forever to get the screws loose enough to slide block plate it.

However once i got those on it was very straight forward. Plug & Play. Hooked everything up and so far so good. Spent 295 instead of 2K or whatever they would of charged for this.

Thank you TW and all the people on this thread that put this information out there.

here's the link in case anyone else needs it.
https://hewitt-tech.com/store/index.php?l=product_list&c=25

 

Curious if anyone has tried this. My dorman injection valves have failed but were still under the 1 year warranty, so i got them free. I don't want to keep doing this, also ive heard people have had issues with the bypass modules failing, if i was in the us i would try it, but being in canada makes returns and what not a pain.

My question is if this would work. Make blocking plates for the exhaust tubes going into the sai housing, Then drilling a small hole in the housing underneath each valve. That way the valve will still open and close normally, still allow air to flow so you wont get the blocked codes, and stop exhaust gasses from getting in and burning up those valves.

Has anyone tried this? Realistically you should be able to unbolt the valve from the housing and still have it all running properly, as far as i know it doesnt sense exhaust flow or back pressure, it only senses if the valves are stuck closed, open or if the pump isnt able to push air. could even stick one of those little black rubber one way valve into them to stop any water from splashing into the holes(i dont think it would make it in there though)

If no one has tried this i may just do it my self. If it works I will make block off plates directly on the manifolds and remove the metal pipes completly.

 

Truck started acting up on my way into work yesterday. Got to work and checked the codes, P2440, P2442, P2431, read the start of this thread and was preparing myself to attempt to come up with $2000. Skipped to the end and saw the reference to TSB 0333-17 called up Toyota Canada and as soon as I mentioned the codes she knew exactly what I was talking about and told me to bring my truck to the nearest dealer and they would take care of it. Booked to go in Monday, I will update with an outcome.

Thanks again TacomaWorld!

 

She is repaired and ready to be picked up tonight at no charge to me. They did try to charge me a $150 diagnostic fee a but I spoke to the SM and told him there is no way I was paying it, that was waved as well.

I said it once and I will say it again thanks, a lot this thread save me a lot of cash!

 

I have just purchased a 2014 Toyota Tacoma DBL cab v6 early in 2018. Probably around 50k for mileage and now have 66k. I’m now receiving PO418 and P2441 codes and it’s the same parts being quoted to be replaced for $2600!! Air injection pump and air switching valve. I own and only purchase Toyota’s and in fact all family members own Toyota. Never any abnormal issues! Love them as I’ve experienced several other brands. I can’t even begin to tell you how disappointed I am in Toyota for not stepping up and replacing these parts. Nothing should fail with any Toyota before 80 - 100k that cost this expensive or is instrumental in the design of the vehicle such as these parts. This is a clear design problem and they know it! You design products and perform ongoing reliability testing to prove out the design. I’m sure they have the data. Anyway, I’m filing a complaint and calling their 800 number etc...just want to let others know it’s on newer models....looks to be same parts and part numbers....

$134 17600-0P040 NOVAPARTS Secondary Air Injection Pump Smog Pump Replacement for 2012 2013 2014 2015 Toyota Tacoma 4.0L V6 17610-0W020

17600-0P040 and 25710-31022.

 

Have you asked about the TSB to get it covered under warranty?

 

I put a call into the Toyota dealer to ask that question. Did not receive a return call yet but will make sure I have a discussion on Monday. This thread is very valuable!

Note this morning I reviewed the assembly and it’s easy to replace the pump assembly compared to previous taco models! I would also say it looks easy to replace the valve assembly on this model year. I only need to remove the air filter compartment.

My goal is to have Toyota back up what they designed.

QUESTION has anyone just replaced the pump and if so, will this correct both OBD codes? OR, doi have to replace both parts?

 

If you don't hear anything from the dealer, just call Toyota's customer support line and they'll take care of it.

 

I have heard back from dealer and no go! According to him Toyota used various suppliers for these parts and our VIN indicates that the parts were not part of the recall. Since I'm in supply chain and Engineering I can tell you that we like to have dual sources in the event of defective parts/sourcing issues. Is this the case? Well, we need to see if there are any identifiers on the parts to validate that statement OR someone from Toyota/service can shed the details. Either way, it is a design problem if its happening on a Taco w/66K miles!!!! I'm seeing other years on this board replacing! In the mean time, will call Toyota 800 331 4331 to see if I can push for coverage.

 

Well I've had a discussion with Toyota directly and have a case #. Anyone know how long it takes? I have to get this vehicle back up and functioning normally. Have to pull the trigger next week!!!

Also, does it matter if I use a 2015 Air Injection pump for 2015 (

$78 17600-0C020 Secondary Air Injection Pump Smog Pump for 2005-2015 Toyota Tacoma Base Pre Runner 2.7L L4 17610-0C020

17600-0C020) in my 2014 (

$134 17600-0P040 NOVAPARTS Secondary Air Injection Pump Smog Pump Replacement for 2012 2013 2014 2015 Toyota Tacoma 4.0L V6 17610-0W020

17600-0P040)? How do I know I have the latest version if in fact purchase a 17600-0P040? Trying to understand if there is revision control involved here and how they distinguish a bad version from a good w/o looking at the tags on the part? Does anyone know the differences?

 

I got the P2442 code a couple weeks ago and reset it (crossed my fingers). Last week it would code / limp mode every time it cooled down and then on Wednesday the P2440 code also would come on. I called local dealer and they got me in that day to T/S the check engine but because I had reset the code they wouldn't touch it. Later that afternoon it went back into limp so I made another appointment for Thursday.

I insured that I had it back to factory condition (Foam and cover without my filter mod) and was expecting problems but was pleasantly surprised. In and out with all new pump, hoses and valve assembly in less than 2 hours all covered under the TSB.

Couple more weeks for this campaign then you will need to be under 125k miles for coverage. If you are getting this code consider having Toyota fix it.

 

I'm pretty sure the letter I received said unlimited miles.

 

Got it! Went back a ways and saw the 2nd notice of unlimited miles, Thanks!

 

UPDATE Toyota reached out to me and will cover ⅔ of part costs. I ordered the parts on line at OEM Toyota parts online for significant savings from my Toyota dealer. My sone and I just finished replacing the parts and it was very easy!!

However, I’m now getting P2441 and P2445! I am resting but continue to get these codes! I’m baffled......checked fuses, connections .....what is left?

 

Lette, are these codes actually triggering the check engine light or are they being stored and read with a scan tool?

One thing that all should know about replacing parts to repair the SAI is your blood pressure may not subside for a while. Its not enough that this horrible system can suddenly put your truck in limp mode in some very dangerous or sketchy places, but you may find that after fixing the problem the bitter taste may linger. The SAI system often leaves codes that can't be immediately cleared, seemingly hanging around to haunt you. The codes will not clear until a drive cycle is completed. This may take some time for some trucks.

 

I don't know if this has been said already, but why can't Toyota put out a TSB in addition to their customer care campaign? While fixing it under warranty is great, why not include a reflash of the ecu so the SAI pump cycles at shutoff like MY 2013 and up? If it's possible for the spark knock issue, I can't imagine a flash coded to tell the fan to cycle at shutoff should be an issue.