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Home >> Toyota >> 2019 >> Sequoia SR5, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 19 (Engine Control System (3UR-FBE) - Diagnostic Codes (6 Of 6)) >> SFI System >> DTC P2440: Secondary Air Injection System Switching Valve Stuck Open Bank1; DTC P2441: Secondary Air Injection System Switching Valve Stuck Close Bank1; DTC P2442: Secondary Air Injection System Switching Valve Stuck Open Bank 2; DTC P2443: Secondary Air Injection System Switching Valve Stuck Closed Bank 2 [10/2016 - 08/2017] >> Procedure

DTC P2440: Secondary Air Injection System Switching Valve Stuck Open Bank1; DTC P2441: Secondary Air Injection System Switching Valve Stuck Close Bank1; DTC P2442: Secondary Air Injection System Switching Valve Stuck Open Bank 2; DTC P2443: Secondary Air Injection System Switching Valve Stuck Closed Bank 2 [10/2016 - 08/2017]: Procedure

WARNING: This page is about a different car, the 2018 Toyota Sequoia, 2017 Toyota Sequoia, and 2016 Toyota Sequoia. However, it is still accessible from the selected car via links, so may be relevant.
  1. CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO SECONDARY AIR INJECTION SYSTEM DTCS) 
    1. Connect the Techstream to the DLC3.
    2. Turn the ignition switch to ON and turn the Techstream on.
    3. Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.
    4. Read DTCs.
      RESULT

      Result Proceed to
      P2440, P2441, P2442 and/or P2443 are output A
      P2440, P2441, P2442 and/or P2443 and P0412 and/or P0415 are output B
      P2440, P2441, P2442 and/or P2443 and other DTCs (except P0412 and P0415) are output C

      If any DTCs other than P0412, P0415, P2440, P2441, P2442 and/or P2443 are output, troubleshoot those DTCs first.

    Result: 

    B 

    GO TO AIR SWITCHING VALVE INSPECTION PROCEDURE (P0412 AND P0415) 

    (Refer to CAUTION / NOTICE / HINT )

    Result: 

    C 

    GO TO DTC CHART 

    (Refer to DIAGNOSTIC TROUBLE CODE CHART [10/2016 - 08/2017] )

    Result: 

    A 

    See step  2

  2. CHECK FREEZE FRAME DATA (AIR PUMP FREEZE, AIR SWITCHING VALVE FREEZE) 
    1. Connect the Techstream to the DLC3.
    2. Turn the ignition switch to ON and turn the Techstream on.
    3. Read the values of Air Pump Freeze, Air Pump2 Freeze, Air Switching Valve Freeze and Air Switching Valve2 Freeze from the freeze frame data recorded previously.
    4. Referring to the following table, proceed to the appropriate step according to the result of the data reading.
      RESULT

      Result Proceed to
      Air Pump Freeze Air Pump2 Freeze Air Switching Valve Freeze Air Switching Valve2 Freeze
      OFF OFF OFF OFF B
      Except above A

    Result: 

    B 

    See step  8

    Result: 

    A 

    See step  3

  3. PERFORM ACTIVE TEST USING TECHSTREAM (ACTIVATE THE AIR PUMP HEATER) 
    1. Disconnect the air pump connector.
      GTY540098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the Techstream to the DLC3.
    3. Turn the ignition switch to ON and turn the Techstream on.
    4. Enter the following menus: Powertrain / Engine and ECT/ Active Test / Activate the Air Pump Heater.
    5. Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connection Condition Specified Condition
      D35-1 (APH+) - Body ground Activate the Air Pump Heater is ON 11 to 14 V
      D36-1 (APH+) - Body ground Activate the Air Pump Heater is ON 11 to 14 V

    Result: 

    NG 

    See step  5

    Result: 

    OK 

    See step  4

  4. INSPECT AIR PUMP (HEATER RESISTANCE) 
    1. Inspect the air pump (Refer to INSPECTION [08/2015 - 08/2018] ).

    Result: 

    NG 

    REPLACE AIR PUMP 

    (Refer to REMOVAL [08/2015 - 08/2018] )

    Result: 

    OK 

    See step  5

  5. INSPECT AIR PUMP HEATER RELAY (AI-HTR) 
    1. Inspect the air pump heater relay (AI-HTR) (Refer to PROCEDURE - Step 7 ).

    Result: 

    NG 

    REPLACE AIR PUMP HEATER RELAY (AI-HTR) 

    Result: 

    OK 

    See step  6

  6. CHECK AIR PUMP HEATER RELAY (AI-HTR) (POWER SOURCE) 
    1. Remove the air pump heater relay (AI-HTR).
    2. Measure the voltage according to the value(s) in the table below.
      GTY549126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      Tester Connection Condition Specified Condition
      AI-HTR relay terminal 3 - Body ground Always 11 to 14 V

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  7

  7. CHECK HARNESS AND CONNECTOR (AIR PUMP - AI-HTR RELAY, BODY) 
    1. Remove the air pump heater relay (AI-HTR).
    2. Disconnect the air pump connector.
    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      AI-HTR relay terminal 5 - D35-1 (APH+) Always Below 1 Ω
      AI-HTR relay terminal 5 - D36-1 (APH+) Always Below 1 Ω
      D35-3 (APHG) - Body ground Always Below 1 Ω
      D36-3 (APHG) - Body ground Always Below 1 Ω
      AI-HTR relay terminal 5 or D35-1 (APH+) - Body ground Always 10 kΩ or higher
      AI-HTR relay terminal 5 or D36-1 (APH+) - Body ground Always 10 kΩ or higher

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  8

  8. INSPECT AIR PUMP 
    1. Inspect the air pump (Refer to ON-VEHICLE INSPECTION [08/2015 - 08/2018] ).

    Result: 

    NG 

    REPLACE AIR PUMP 

    (Refer to REMOVAL [08/2015 - 08/2018] )

    Result: 

    OK 

    See step  9

  9. PERFORM ACTIVE TEST USING TECHSTREAM 
    GTY729918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Visual check
      1. Start the engine and warm it up.
      2. Turn the ignition switch off.
      3. Disconnect the No. 2 air hose and No. 3 air hose.
      4. Connect the Techstream to the DLC3.
      5. Turn the ignition switch to ON and turn the Techstream on.
      6. Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Manual Mode / AIR PUMP 1: ON, ASV1: OPEN, AIR PUMP 2: ON, ASV2: OPEN.

        HINT: 

        When Manual Mode is selected, the Techstream initialization (atmospheric pressure measurement) is performed automatically. The initialization takes 10 seconds. After the initialization, AP and ASV operation can be selected.

      7. Start the engine.
      8. Perform the AIR system intrusive operation while the engine is idling.
      9. Place your hand near the air switching valve port and check that the exhaust gas pressure pulsates when the ASV is turned ON.
        WARNING:

        To avoid the danger of being burned by the exhaust gas, bring your hand close to the valve port slowly.

      10. Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Manual Mode / AIR PUMP 1: ON, ASV1: OPEN, AIR PUMP 2: ON, ASV2: OPEN and AIR PUMP 1: ON, ASV1: CLOSE, AIR PUMP 2: ON, ASV2: CLOSE.
      11. Check that the exhaust gas does not pulsate when the ASV is turned OFF.
      12. Turn the ignition switch off.
        NOTE:
        • This Secondary Air Injection Check only allows technicians to operate the AIR system for a maximum of 5 seconds. Furthermore, the check can only be performed up to 4 times per trip. If the test is repeated, intervals of at least 30 seconds are required between checks.

          While AIR system operation using the Techstream is prohibited, the Techstream display indicates the prohibition (WAIT or ERROR).

          If an ERROR is displayed on the Techstream during the test, stop the engine for 10 minutes, and then try again.

        • Performing the Secondary Air Injection Check repeatedly may cause damage to the AIR system. If necessary, leave an interval of several minutes between System Check operations to prevent the system from overheating.
        • When performing the Secondary Air Injection Check operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch turned to ON or the engine running.
        • Turn the ignition switch off when the Secondary Air Injection Check operation finishes.

        Standard

        Air Pump Operations ASV Operations Exhaust Gas Pulsation
        ON OFF Not detected
        ON ON Detected
    2. Other inspection method:

      The ASV operation can be confirmed by checking the cumulative pressure pulsation* provided in the System Check.

      Perform System Check operation under Manual Mode.

      *: The exhaust pulsation value is calculated in the ECM. If the calculated value exceeds a certain level, the ECM determines that the exhaust pulsation is in the AIR system.

      1. Start the engine and warm it up.
      2. Turn the ignition switch off.
      3. Connect the Techstream to the DLC3.
      4. Turn the ignition switch to ON and turn the Techstream on.
      5. Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Manual Mode / AIR PUMP 1: ON, ASV1: OPEN, AIR PUMP 2: ON, ASV2: OPEN and AIR PUMP 1: OFF, ASV1: CLOSE, AIR PUMP 2: OFF, ASV2: CLOSE.
      6. Start the engine after the Techstream initialization is finished.
      7. Perform the AIR system intrusive operation while the engine is idling.
      8. Check that the air-fuel ratio and pressure in the secondary air injection system passage (PULSATION) displayed on the Techstream indicate the conditions shown in the table below.
      9. Turn the ignition switch off.

      OK

      AIR System Operation Pulsation Condition
      (ECM Calculation)      		 Air-Fuel Ratio
      (Reference)
      AIR PUMP: ON, ASV: OPEN 10 kPa or more 18 or more
      AIR PUMP: OFF, ASV: CLOSE Less than 30 kPa Approximately 14.5
      (around stoichiometric air-fuel ratio)

      Reference:

      If the air pump operation is confirmed as normal (Refer to DTC P2444: Secondary Air Injection System Pump Stuck On Bank1; DTC P2445: Secondary Air Injection System Pump Stuck Off Bank1; DTC P2446: Secondary Air Injection System Pump Stuck On Bank 2; DTC P2447: Secondary Air Injection System Pump Stuck Off Bank 2 [10/2016 - 08/2017] ), the air-fuel ratio detected in front of three-way catalytic converter changes in response to the secondary air pumped into the exhaust port when the air pump operates.

      RESULT

      Result Proceed to
      NG A
      OK B

    Result: 

    B 

    See step  17

    Result: 

    A 

    See step  10

  10. INSPECT AIR TUBE (BLOCKAGES AND LEAKAGES) 
    GTY593636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Check that the No. 2 and No. 3 air tubes are securely connected to both the exhaust manifold and the ASV.
    2. Inspect the air tube for blockages and damage.

      OK

      No blockages and damage on intake pipe.

    Result: 

    NG 

    REPLACE AIR TUBE 

    (Refer to REMOVAL [08/2015 - 08/2018] )

    Result: 

    OK 

    See step  11

  11. INSPECT AIR SWITCHING VALVE ASSEMBLY 
    1. Inspect the air switching valve assembly (Refer to INSPECTION [08/2015 - 08/2018] ).

    Result: 

    NG 

    REPLACE AIR SWITCHING VALVE ASSEMBLY 

    (Refer to REMOVAL [08/2015 - 08/2018] )

    Result: 

    OK 

    See step  12

  12. INSPECT AIR INJECTION CONTROL DRIVER (POWER SOURCE OF AIR INJECTION CONTROL DRIVER) 
    GTY549147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the D31 and D32 or D33 and D34 AID connectors.
    2. Turn the ignition switch to ON.
    3. Measure the voltage according to the value(s) in the table below.

      Standard voltage

      Tester Connection Switch Condition Specified Condition
      D31-1 (BATT) - Body ground Always 11 to 14 V (near battery voltage)
      D32-5 (+B) - Body ground Ignition switch ON 11 to 14 V (near battery voltage)
      D33-1 (BAT2) - Body ground Always 11 to 14 V (near battery voltage)
      D34-5 (+B2) - Body ground Ignition switch ON 11 to 14 V (near battery voltage)
    4. Measure the resistance according to the value(s) in the table below.

      Standard resistance

      Tester Connection Condition Specified Condition
      D32-1 (E) - Body ground Always Below 1 Ω
      D34-1 (E2) - Body ground Always Below 1 Ω

    Result: 

    NG 

    REPAIR OR REPLACE AIR INJECTION CONTROL DRIVER POWER SOURCE CIRCUIT 

    Result: 

    OK 

    See step  13

  13. CHECK HARNESS AND CONNECTOR (ECM - AIR INJECTION CONTROL DRIVER) 
    1. Disconnect the A27 or D56 ECM connector.
    2. Disconnect the D32 or D34 AID connector.
    3. Measure the resistance according to the value(s) in the table below.

      Standard resistance

      Tester Connection Condition Specified Condition
      D56-28 (AIRV) - D32-3 (SIV) Always Below 1 Ω
      A27-43 (ARV2) - D34-3 (SIV2) Always Below 1 Ω
      D56-28 (AIRV) or D32-3 (SIV) - body ground Always 10 kΩ or higher
      A27-43 (ARV2) or D34-3 (SIV2) - body ground Always 10 kΩ or higher

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    See step  14

  14. PERFORM ACTIVE TEST USING TECHSTREAM 
    1. Disconnect the D32 or D34 AID connector.
      GTY577113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect terminals DI and SIV or DI2 and SIV2 of the wire harness connector for the AID.
    3. Connect the Techstream to the DLC3.
    4. Turn the ignition switch to ON and turn the Techstream on.
    5. Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Manual Mode / AIR PUMP 1: ON, ASV 1: OPEN, AIR PUMP 2: ON, ASV 2: OPEN.

      HINT: 

      When Manual Mode is selected, the Techstream initialization (atmospheric pressure measurement) is performed automatically. The initialization takes 10 seconds. After the initialization, AIR PUMP and ASV operation can be selected.

    6. Start the engine.
    7. Perform the AIR system forced operation while the engine is idling.
    8. Measure the voltage between the SIV and E or SIV2 and E2 terminals of the ECM connector when the AIR system is ON and OFF.
    9. Turn the ignition switch off.
      NOTE:
      • Performing Secondary Air Injection Check repeatedly may cause damage to the secondary air injection system. If it is necessary to repeat the check, leave an interval of several minutes between System Check operations to prevent the system from overheating.
      • When performing the Secondary Air Injection Check operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch ON or the engine running.
      • Turn the ignition switch off when the Secondary Air Injection Check operation finishes.

      Standard Voltage

      Tester Connection Condition Specified Condition
      D32-3 (SIV) - D32-1 (E) AIR PUMP: ON, ASV: OPEN 0.5 to 2 V
      D34-3 (SIV2) - D34-1 (E2) AIR PUMP: ON, ASV: OPEN 0.5 to 2 V
      D32-3 (SIV) - D32-1 (E) AIR PUMP: OFF, ASV: CLOSE 11 to 14 V
      D34-3 (SIV2) - D34-1 (E2) AIR PUMP: OFF, ASV: CLOSE 11 to 14 V
    10. Connect terminals DI and SIP or DI2 and SIP2 of the wire harness connector for the AID.
      GTY577115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Connect the Techstream to the DLC3.
    12. Turn the ignition switch to ON and turn the Techstream on.
    13. Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Manual Mode / AIR PUMP 1: ON, ASV 1: OPEN, AIR PUMP 2: ON, ASV 2: OPEN.

      HINT: 

      When Manual Mode is selected, the Techstream initialization (atmospheric pressure measurement) is performed automatically. The initialization takes 10 seconds. After the initialization, AIR PUMP and ASV operation can be selected.

    14. Start the engine.
    15. Perform the AIR system forced operation while the engine is idling.
    16. Measure the voltage between the SIP and E or SIP2 and E2 terminals of the ECM connector when the AIR system is ON and OFF.
    17. Turn the ignition switch off.
      NOTE:
      • Performing Secondary Air Injection Check repeatedly may cause damage to the secondary air injection system. If it is necessary to repeat the check, leave an interval of several minutes between System Check operations to prevent the system from overheating.
      • When performing the Secondary Air Injection Check operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch ON or the engine running.
      • Turn the ignition switch off when the Secondary Air Injection Check operation finishes.

      Standard Voltage

      Tester Connection Condition Specified Condition
      D32-4 (SIP) - D32-1 (E) AIR PUMP: ON, ASV: OPEN 0.5 to 2 V
      D34-4 (SIP2) - D34-1 (E2) AIR PUMP: ON, ASV: OPEN 0.5 to 2 V
      D32-4 (SIP) - D32-1 (E) AIR PUMP: OFF, ASV: CLOSE 11 to 14 V
      D34-4 (SIP2) - D34-1 (E2) AIR PUMP: OFF, ASV: CLOSE 11 to 14 V

    Result: 

    NG 

    REPLACE ECM 

    (Refer to REMOVAL [08/2015 - 08/2018] )

    Result: 

    OK 

    See step  15

  15. REPLACE AIR INJECTION CONTROL DRIVER 
    1. Replace the air injection control driver (Refer to REMOVAL [08/2015 - 08/2018] ).

    Result: 

    NEXT 

    See step  16

  16. CHECK WHETHER DTC OUTPUT RECURS (DTC P2440, P2441, P2442 AND/OR P2443) 
    1. Start the engine and warm it up.
    2. Turn the ignition switch off.
    3. Connect the Techstream to the DLC3.
    4. Turn the ignition switch to ON and turn the Techstream on.
    5. Clear DTCs (if output) (Refer to DTC CHECK / CLEAR [08/2015 - 08/2018] ).
    6. Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Automatic Mode.
    7. Start the engine after the Techstream initialization is finished.
    8. Perform the System Check operation by pressing Next.
    9. After operating the AIR system, perform the following to confirm the AIR system pending codes: Press the Exit button.
    10. Check pending DTCs.
    11. Turn the ignition switch off.

      OK

      No pending DTC output.

      NOTE:
      • When performing the Secondary Air Injection Check operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch turned to ON or the engine running.
      • Turn the ignition switch off when the Secondary Air Injection Check operation finishes.

    Result: 

    OK 

    END 

    Result: 

    NG 

    REPLACE ECM 

    (Refer to REMOVAL [08/2015 - 08/2018] )

  17. INSPECT VACUUM HOSES (AIR SWITCHING VALVE - PRESSURE SENSOR) 

    OK

    No blockage and no deformation in vacuum hose.

    Result: 

    NG 

    REPAIR OR REPLACE VACUUM HOSE 

    Result: 

    OK 

    See step  18

  18. INSPECT AIR SWITCHING VALVE ASSEMBLY (PRESSURE SENSOR) 

    See step  2

    Result: 

    OK 

    CHECK FOR INTERMITTENT PROBLEMS 

    (Refer to CHECK FOR INTERMITTENT PROBLEMS [08/2015 - 08/2018] )

    Result: 

    NG 

    REPLACE AIR SWITCHING VALVE ASSEMBLY 

    (Refer to REMOVAL [08/2015 - 08/2018] )

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