Secondary air injection system P2440 and P2442

Customer Support Program ZHA

 

I got CEL P2440 this week on my 2005 2.7L, I'm going to contact my local dealer to see if I can get covered; I ordered the parts from Norwalk Toyota and they're currently in the mail.
I ordered the Valve and Pump Cover and the 1" Uni Filter off Amazon to remedy this myself.

 

Just got the letter in the mail today, but haven't had any problems yet. 2012 4.0L with 65,000 miles on it. I'm assuming these will eventually fail on most of the trucks at some time? If I went to my dealer and told him it threw the codes but I cleared them (wink wink) and they haven't returned yet they should replace it before I break down somewhere.

 

I decided to just install myself.
P/N 25710-75015

Due to the thicker mounting flange the Studs must be replaced with P/N 90126-08031.

 

So it is actually a different part. That's good to know.

 

i bought slyfox75's kit, which does the same thing as the Hewitt kit but is only $48. it also requires you to have a working pump and mine had failed. so i bought a Dorman 306-010 pump, which is an exact replica of the tacoma pump with the exception being the wire connector. i swapped wires from my old pump to the new pump. then i made a block off plate to isolate the valve from the exhaust gasses and now i am good to go. the total cost for me was $138.00. this is a good option if toyota will not replace for free. my truck is a 2013 but it carries a flood title and has no warranty coverage, so this was the cheapest route for me. hope this helps some of you.

 

The sly fox kit did not work on my 2012. The pump still ran, as did @Pigpen when he installed it.

 

it works on mine. the pump doesn't run and no more check engine light. but i haven't had it installed very long so time will tell.

 

Got my letter in the mail yesterday. Both my valves and the pump were replaced under a good will warranty a year or 2 back. Truck only had about 34-36K miles on it best I remember. Has only 42,000 on it now.
If I read this right they are covered for 10 years 150,000 miles under the secondary coverage. Best I can tell the difference between Primary and Secondary coverage is after the Primary expires the Secondary only has a 10 year 150,000 mile limit. Both cover the parts and labor the same as would be covered under the new car warranty guidelines. Anyone see it differently?

 

It worked on a 4.0? Or are you 4 cyl? It works on the 4 cyl.

 

my truck is a 4cyl. i spoke too soon though, as my check engine light reappeared a couple of days ago.

 

It's fantastic that Toyota USA is offering this warranty. Unfortunately I live in Canada where Toyota have issued a similar bulletin on 10th January 2018 offering a warranty of 36 months or 60000 kms. Useful for a 5 year old 2012 vehicle and a sure sign that they care about their customers and their ongoing driving experience...

My 2012 Tacoma TRD Sport V6 went into limp mode a week ago at 56456 kms. The code was P2442, "secondary air injection valve stuck open bank 2". I bought it new at Nanaimo Toyota and it has been fully dealer serviced by them since. The dealer contacted Toyota who refused to help me. Then I contacted Toyota Customer Service, to be told my vehicle was different to a US vehicle (despite identical parts numbers) and that this was not a common problem with Tacomas in Canada. Maybe the air or the rain are different up here?

Since neither the dealer (Nanaimo Toyota) or Toyota Canada were willing to help me in any way, I went with the Tundra Dorman valve option that someone posted on this thread. Thank you for the suggestion and for posting - it worked and my truck is up and running again for a lot less than Nanaimo Toyota would have charged me. For the record, they quoted $2633 plus taxes. I purchased the Dorman valves from Lordco for $476 plus tax. Although my pump filter was intact, I have removed it and installed a $30 K&N external filter instead, to prevent the foam disintegrating and being drawn through the pump. Again, thank you for this recommendation.

I love my Tacoma, but this experience has left me seriously jaded with Toyota and questioning whether I will buy from them again.


On a lighter note, I accidentally discovered that these vehicles have an electronic actuator to unlock the driver's door. I am used to working on 50's -70's VWs where everything is manual. I had dismantled everything the previous night to determine the state of the valves. Then I dropped the hood, manually locked the doors and left it for the night - with the battery disconnected. Then yesterday morning I tried to unlock the driver's door only to find that the key did nothing. A quick "Oh *$#*" moment and a Google search later revealed that you have to pull the handle first and then turn the key if the battery is dead. My heart rate returned to normal! I won't be trying that again.

 

Check the power source. You might not have proper contact where you put the wires in with the relay.

 

Was coming to post this i just received a letter in the mail. I paid 100$ to have this repaired since i had extended warranty. I'm going to try to get that reimbursed. If you guys did it yourself at least try to get your money on the parts

 

I have one with about 40k. I just received this letter. I do also have an extended warrenty. It’s funny, but I do now hope that it fails as soon as possible since it’s going to happen anyway just don’t want it to let go while I’m far from home.

 

Received my letter yesterday, guess I'm gonna get $109.50 back!

 

So basically a month before the letter I got the P2440 and P2442 codes. After ordering the aftermarket Tundra valves and finding out they were backordered over a month, I decided to suck it up and go with the $500 factory Toyota replacement part. I installed it myself (since there was no chance of a warranty fix for my 80k mile truck), issue went away, and then received the lovely letter. Since the letter discusses providing proof of repair (including a diagnostic check, purchase of parts, and installation) to get a refund, has anyone gotten a refund that replaced these parts themselves with only a receipt as evidence?

 

They should cover it if you still have the receipts. You just saved them the labor part.

 

I would submit copies of what you have and type out something explaining your situation and include it.

 

Just received my letter today. I can't believe it. I was lucky not to have paid for my repair, because my dealership covered it. But it's great to have the additional warranty for another 6 years, in case it happens again.