Toyota Tundra Service Manual: Secondary Air Injection System Switching Valve Stuck Open Bank1 (P2440-P2443)

Toyota Tundra Service Manual / Engine, Hybrid System / 1ur-fe Engine Control / Sfi System / Secondary Air Injection System Switching Valve Stuck Open Bank1 (P2440-P2443)

DESCRIPTION

Refer to DTC P0412 (See page ).

DTC No.

DTC Detection Condition

Trouble Area

P2440

Cumulative pressure pulsation is 60 kPa (450 mmHg) or more for 2 seconds (1 trip detection logic).

  • Air switching valve (ASV) assembly
  • Open or short in ASV circuit
  • Secondary air injection system piping
  • Pressure sensor
  • Pressure sensor circuit
  • Air injection control driver (AID)
  • ECM

The air switching valve (for bank 1) is stuck open for 7 seconds while the engine is running (2 trip detection logic).

P2441

The air switching valve (for bank 1) is stuck close for 7 seconds while the engine is running (2 trip detection logic).

  • Air switching valve (ASV) assembly
  • Open or short in ASV circuit
  • Vacuum hose (ASV - pressure sensor)
  • Secondary air injection system piping
  • Pressure sensor
  • Pressure sensor circuit
  • Air injection control driver (AID)
  • Open or short in air pump heater circuit
  • Air pump heater relay (AI HTR)
  • Air pump assembly
  • ECM

P2442

Cumulative pressure pulsation is 60 kPa (450 mmHg) or more for 2 seconds (1 trip detection logic).

  • Air switching valve (ASV) assembly
  • Open or short in ASV circuit
  • Secondary air injection system piping
  • Pressure sensor
  • Pressure sensor circuit
  • Air injection control driver (AID)
  • ECM

The air switching valve (for bank 2) is stuck open for 7 seconds while the engine is running (2 trip detection logic).

P2443

The air switching valve (for bank 2) is stuck close for 7 seconds while the engine is running (2 trip detection logic).

  • Air switching valve (ASV) assembly
  • Open or short in ASV circuit
  • Vacuum hose (ASV - pressure sensor)
  • Secondary air injection system piping
  • Pressure sensor
  • Pressure sensor circuit
  • Air injection control driver (AID)
  • Open or short in air pump heater circuit
  • Air pump heater relay (AI HTR)
  • Air pump assembly
  • ECM

HINT:

Air switching valve normal operation:

When the Air Switching Valve (ASV) is open, exhaust gas pulsation occurs in the secondary air passage.

When the ASV is closed, exhaust gas pulsation does not occur in the secondary air passage.

MONITOR DESCRIPTION

The ECM monitors the pressure in the secondary air passage using the pressure sensor connected to the ASV of the Secondary Air Injection (AIR) system.

If either of the following conditions occurs, the ECM interprets it as a malfunction of the AIR system, and illuminates the MIL and stores a DTC:

  • Exhaust gas pulsation is detected by the pressure sensor despite the ECM commanding the ASV to close.
  • Exhaust gas pulsation is not detected by the pressure sensor despite the ECM commanding the ASV to open.

MONITOR STRATEGY

Related DTCs

P2440: Air control valve stuck open

P2441: Air control valve stuck closed

P2442: Air control valve stuck open

P2443: Air control valve stuck closed

Required Sensors/Components (Main)

Pressure sensor

Required Sensors/Components (Related)

-

Frequency of Operation

Continuous: P2440 Case 2, P2442 Case 2

Once per drive cycle: Others

Duration

2 seconds: P2440 Case 2, P2442 Case 2

7 seconds: Others

MIL Operation

1 driving cycle: P2440, P2442

2 driving cycles: Others

Sequence of Operation

None

TYPICAL ENABLING CONDITIONS

All

Monitor runs whenever following DTCs not present

P0010, P0020 (VVT oil control valve)

P0011, P0021 (VVT system - Advance)

P0012, P0022 (VVT system - Retard)

P0013, P0023 (Exhaust VVT oil control valve)

P0014, P0024 (Exhaust VVT system - Advance)

P0015, P0025 (Exhaust VVT system - Retard)

P0016, P0018 (VVT system - Misalignment)

P0017, P0019 (Exhaust VVT system - Misalignment)

P0031, P0032, P0051, P0052, P101D, P103D (Air fuel ratio sensor heater)

P006A, P0107, P0108 (Manifold absolute pressure)

P0102, P0103 (Mass air flow meter)

P0112, P0113 (Intake air temperature sensor)

P0115, P0117, P0118 (Engine coolant temperature sensor)

P0120, P0121, P0122, P0123, P0220, P0222, P0223, P2135 (Throttle position sensor)

P0125 (Insufficient Coolant Temperature for Closed Loop Fuel Control)

P014C, P014D, P014E, P014F, P015A, P015B, P015C, P015D, P2195, P2196, P2197, P2198, P2237, P2238, P2239, P2240, P2241, P2242, P2252, P2253, P2255, P2256 (Air fuel ratio sensor)

P0171, P0172, P0174, P0175 (Fuel system)

P0301 - P0308 (Misfire)

P0327, P0328, P032C, P032D, P0332, P0333, P033C, P033D (Knock Sensor)

P0335 (Crankshaft position sensor)

P0340, P0342, P0343, P0345, P0347, P0348 (VVT sensor)

P1340 (Camshaft position sensor)

P0351 - P0358 (Igniter)

P0365, P0367, P0368, P0390, P0392, P0393 (Exhaust VVT sensor)

P0401 (EGR system)

P0451, P0452, P0453 (Evaporative Emission System Pressure Sensor)

P0500 (Vehicle speed sensor)

P106B (Evap. emission control system Pressure Sensor - Air Injection System Pressure Sensor correlation)

P219A, P219B, P219C, P219D, P219E, P219F, P21A0, P21A1, P21A2, P21A3 (Air-fuel ratio imbalance)

P2431, P2432, P2433, P2436, P2437, P2438 (Secondary Air Injection System Pressure Sensor)

P2440 (Case 1), P2441, P2442 (Case 1), P2443

Battery voltage

11 V or more

Atmospheric pressure

45 kPa (338 mmHg) or more

Engine

Running

AIR monitor during AIR: ON*1

Completed

AIR monitor during AIR: OFF*2

Completed

AIR injection driver fail (open/short or out of range)

Not detected

AIR pressure sensor fail (open/short or out of range)

Not detected

*1: AIR monitor during AIR: ON

-

Time after AIR in operation

5 seconds or more

AIR pump

ON

AIR valve

Open

Engine speed

400 to 3750 rpm

Intake air amount

Less than 100 gm/s

Time after engine start

1 second or more

*2: AIR monitor during AIR: OFF

-

Time after AIR in operation

10 seconds or more

AIR pump

OFF

AIR valve

Close

Engine speed

Below 3000 rpm

AIR monitor during AIR: ON

Completed

Time after engine start

1 second or more

P2440, P2442 AIR valve is stuck open (Case 2)

One of the following conditions is met

(a), (b) or (c)

(a) Cumulative intake air amount

100 gm/s or more

(b) Difference between starting temperature and current temperature

10°C (18°F) or higher

(c) Starting coolant temperature

60°C (140°F) or higher

AIR pump

OFF

AIR valve

Close

Engine speed

3750 rpm or less

AIR pressure sensor fail (open/short or out of range)

Not detected

Time after engine started

1 second or more

Time after AIR in operation

10 seconds or more

AIR valve open stuck

Not detected

AIR pressure sensor open stuck (DTC P2445, P2447)

Not in operation

Engine load

20% or more

TYPICAL MALFUNCTION THRESHOLDS

Secondary Air Injection ON (Condition 1)

Both conditions are met during AIR ON

-

Cumulative pressure pulsation

18 kPa or higher

AIR pressure

1.9 kPa or higher

Secondary Air Injection ON (Condition 2)

Both conditions are met during AIR ON

-

Cumulative pressure pulsation

18 kPa or higher

AIR pressure

Below 1.9 kPa

Secondary Air Injection ON (Condition 3)

Both conditions are met during AIR ON

-

Cumulative pressure pulsation

Below 18 kPa

AIR pressure

1.9 kPa or higher

Secondary Air Injection ON (Condition 4)

Both conditions are met during AIR ON

-

Cumulative pressure pulsation

Below 18 kPa

AIR pressure

Below 1.9 kPa

Secondary Air Injection OFF (Condition 1)

Both conditions are met during AIR OFF

-

Cumulative pressure pulsation

25 kPa or higher

AIR pressure

3 kPa or higher

Secondary Air Injection OFF (Condition 2)

Both conditions are met during AIR OFF

-

Cumulative pressure pulsation

25 kPa or higher

AIR pressure

Below 3 kPa

Secondary Air Injection OFF (Condition 3)

Both conditions are met during AIR OFF

-

Cumulative pressure pulsation

Below 25 kPa

AIR pressure

3 kPa or higher

Secondary Air Injection OFF (Condition 4)

Both conditions are met during AIR OFF

-

Cumulative pressure pulsation

Below 25 kPa

AIR pressure

Below 3 kPa

P2440, P2442 AIR valve is stuck open (Case 1)

Either condition is met

(a) or (b)

(a) AIR OFF Condition 1

Met

(b) AIR OFF Condition 2

Met

P2441, P2443 AIR valve is stuck closed

Either condition is met

(a) or (b)

(a) AIR ON Condition 3

Met

(b) AIR ON Condition 4

Met

P2440, P2442 AIR valve is stuck open (Case 2)

Cumulative pressure pulsation

75 kPa or higher

MONITOR RESULT

Refer to Checking Monitor Status (See page ).

CONFIRMATION DRIVING PATTERN

NOTICE:

  • 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 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.
  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.
  5. Turn the Techstream on.
  6. Clear DTCs (if set) (See page ).
  7. Turn the ignition switch off and wait for at least 30 seconds.
  8. Turn the ignition switch to ON and turn the Techstream on.
  9. Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Automatic Mode.
  10. Start the engine after the Techstream initialization is finished.
  11. Perform the System Check operation by pressing ENTER (Next).
  12. Perform the following to confirm the AIR system pending codes: Press ENTER (Exit).
  13. Check for pending DTCs.

    OK:

    No pending DTC is output.

  14. After the "Secondary air injection check" is completed, check for All Readiness by entering the following menus: Powertrain / Engine and ECT / Utility / All Readiness.
  15. Input the DTC: P2440, P2441, P2442 or P2443.
  16. Check the DTC judgment result.

    Tester Display

    Description

    NORMAL

    • DTC judgment completed
    • System normal

    ABNORMAL

    • DTC judgment completed
    • System abnormal

    INCOMPLETE

    • DTC judgment not completed
    • Perform driving pattern after confirming DTC enabling conditions

    N/A

    • Unable to perform DTC judgment
    • Number of DTCs which do not fulfill DTC preconditions has reached ECU memory limit

    HINT:

    • If the judgment result shows NORMAL, the system is normal.
    • If the judgment result shows ABNORMAL, the system has a malfunction.
  17. If the test result is INCOMPLETE or N/A and no pending DTC is output, perform a universal trip and check for permanent DTCs (See page ).

    HINT:

    • If no permanent DTC is output, the system is normal.
    • If a permanent DTC is output, the system is malfunctioning.
  18. Turn the ignition switch off.

WIRING DIAGRAM

Refer to DTC P0412 (See page ).

CAUTION / NOTICE / HINT

HINT:

  • Bank 1 refers to the bank that includes the No. 1 cylinder*.

    *: The No. 1 cylinder is the cylinder which is farthest from the transmission.

  • Bank 2 refers to the bank that does not include the No. 1 cylinder.

HINT:

Determination by ECM monitoring:

The ECM locates malfunctions in the Secondary Air Injection (AIR) system by detecting the pressure in the AIR passage between the air pump and Air Switching Valve (ASV) and stores a DTC. Soon after a cold engine start, the monitor runs for a short time while the AIR system is both ON and OFF. The ECM detects both the pressure and the exhaust pulsation and compares them.

The following 8 patterns are AIR system pressure conditions in the AIR system passage.

Pressure Condition in Secondary Air Injection System Case 1

Air Pump

ON

Air Switching Valve

Open

Pressure

1.9 kPa or more

Pulsation Detection

Exhaust gas pulsation detected

Pressure Condition in Secondary Air Injection System Case 2

Air Pump

OFF

Air Switching Valve

Open

Pressure

Less than 3.0 kPa

Pulsation Detection

Exhaust gas pulsation detected

Pressure Condition in Secondary Air Injection System Case 3

Air Pump

ON

Air Switching Valve

Closed

Pressure

1.9 kPa or more

Pulsation Detection

Exhaust gas pulsation not detected

Pressure Condition in Secondary Air Injection System Case 4

Air Pump

OFF

Air Switching Valve

Closed

Pressure

Less than 3.0 kPa

Pulsation Detection

Exhaust gas pulsation not detected

Pressure Condition in Secondary Air Injection System Case 5

Air Pump

ON

Air Switching Valve

Open

Pressure

1.9 kPa or more

Pulsation Detection

Exhaust gas pulsation detected

Pressure Condition in Secondary Air Injection System Case 6

Air Pump

OFF

Air Switching Valve

Open

Pressure

Less than 3.0 kPa

Pulsation Detection

Exhaust gas pulsation detected

Pressure Condition in Secondary Air Injection System Case 7

Air Pump

ON

Air Switching Valve

Closed

Pressure

1.9 kPa or more

Pulsation Detection

Exhaust gas pulsation not detected

Pressure Condition in Secondary Air Injection System Case 8

Air Pump

OFF

Air Switching Valve

Closed

Pressure

Less than 3.0 kPa

Pulsation Detection

Exhaust gas pulsation not detected

If the detected pressure is high, the air pump is assumed to be ON and if it alternates sharply, the ASV is assumed to be open. The ECM locates malfunctions from the combination of pressures detected when the AIR system is ON and OFF.

HINT:

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.

HINT:

  • In case 3 and 7, as the pressure sensor detects a slight pump operation pulsation, the detected value is not constant. Since the pump outlet is blocked by closing the ASV, the average pressure is higher than in case 1 (approximately 18 to 25 kPa).
  • In case 1, the average pressure is approximately 3 to 11 kPa. The value of 1.9 kPa indicated in the table above is a threshold for detecting pump malfunctions.

Detected Condition while AIR Operating:

Air Pump ON, ASV Open

Detected Condition while AIR not Operating:

Air Pump OFF, ASV Closed

ECM Determination

DTC Output

Case 1

Case 8

Normal

-

Case 1

Case 6

Air switching valve stuck open

P2440

or

P2442

Case 1

Case 7

Air pump stuck ON

P2444

or

P2446

Case 2

Case 8

Air pump stuck OFF

P2445

or

P2447

Case 3

Case 8

Air switching valve stuck closed

P2441

or

P2443

Case 1

Case 5

Air switching valve stuck open and air pump stuck ON

P2440 and P2444

or

P2442 and P2446

Case 2

Case 6

Air switching valve stuck open and air pump stuck OFF

P2440 and P2445

or

P2442 and P2447

Case 3

Case 7

Air switching valve stuck closed and air pump stuck ON

P2441 and P2444

or

P2443 and P2446

Case 4

Case 8

Air switching valve stuck closed and air pump stuck OFF

P2441 and P2445

or

P2443 and P2447

HINT:

  • By using the Techstream to perform the Secondary Air Injection Check operation in the System Check, the air-fuel ratio and the pressure in the secondary air injection system passage can be checked while the secondary air injection system is operating. This helps technicians to troubleshoot the system when it malfunctions. Furthermore, pending codes also can be checked by performing Utility / Secondary Air Injection Check / Automatic Mode after the repair.
  • Read freeze frame data using the Techstream. Freeze frame data records the engine condition when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred.
  • System Check:
  • The pressure in the secondary air passage can be checked using the Techstream.
    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.
    5. 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 and AIR PUMP 1: OFF, ASV1 CLOSE, AIR PUMP 2: OFF, ASV2 CLOSE.

      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.

    7. Start the engine.
    8. Perform the AIR system forced operation while the engine is idling.
    9. Check that the air pump (AIR PUMP), ASV and pressure in the AIR system passage (PRESSURE) displayed on the Techstream indicate the conditions shown in the table below.

      Standard:

      Tester Operation

      Air Pump

      ASV

      Pressure*1

      Pulsation*2

      AIR PUMP: ON, ASV: OPEN

      ON

      OPEN

      1.9 kPa or more

      18 kPa or more

      AIR PUMP: OFF, ASV: CLOSE

      OFF

      CLOSE

      Less than 3.0 kPa

      Less than 25 kPa

      *1: Average pumping pressure (gauge pressure). The pressure should be 1.9 kPa or more when the AIR system operates.

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

    10. Turn the ignition switch off.

      NOTICE:

      • 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 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.

PROCEDURE

1.

CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO SECONDARY AIR INJECTION SYSTEM DTCS)

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) Turn the Techstream on.

(d) Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.

(e) Read DTCs.

Result

Result

Proceed to

P2440, P2441, P2442 and/or P2443 is 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.

B

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

C

GO TO DTC CHART

A

2.

PERFORM ACTIVE TEST USING TECHSTREAM (ACTIVATE THE AIR PUMP HEATER)

(a) Disconnect the air pump assembly (for bank 1 or Bank 2) connector.

(b) Connect the Techstream to the DLC3.

(c) Turn the ignition switch to ON and turn the Techstream on.

(d) Enter the following menus: Powertrain / Engine and ECT/ Active Test / Activate the Air Pump Heater.

(e) Measure the voltage according to the value(s) in the table below.

Standard Voltage

Tester Connection

Condition

Specified Condition

D89-1 (APH+) - Body ground

Activate the Air Pump Heater is ON

11 to 14 V

D90-1 (APH+) - Body ground

Activate the Air Pump Heater is ON

11 to 14 V

(f) Reconnect the air pump assembly (for bank 1 or Bank 2) connector.

NG

GO TO STEP 4

OK

3.

INSPECT AIR PUMP ASSEMBLY (FOR BANK 1 OR BANK 2) (HEATER RESISTANCE)

(a) Inspect the air pump assembly (for bank 1 or bank 2) (See page ).

NG

REPLACE AIR PUMP ASSEMBLY (FOR BANK 1 OR BANK 2)

OK

4.

INSPECT AIR PUMP HEATER (AI HTR) RELAY

NG

REPLACE AIR PUMP HEATER (AI-HTR) RELAY

OK

5.

CHECK AIR PUMP HEATER (AI HTR) RELAY (POWER SOURCE)

(a) Remove the air pump heater (AI HTR) relay.

(b) Measure the voltage according to the value(s) in the table below.

Standard Voltage

Tester Connection

Condition

Specified Condition

AI HTR relay terminal 5 - Body ground

Always

11 to 14 V

(c) Reinstall the air pump heater (AI-HTR) relay.

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

6.

CHECK HARNESS AND CONNECTOR (AIR PUMP ASSEMBLY - AI HTR RELAY, BODYGROUND)

(a) Remove the air pump heater (AI HTR) relay.

(b) Disconnect the air pump assembly (for bank 1 or bank 2) connector.

(c) Measure the resistance according to the value(s) in the table below.

Standard Resistance

Tester Connection

Condition

Specified Condition

AI HTR relay terminal 3 - D89-1 (APH+)

Always

Below 1 Ω

AI HTR relay terminal 3 - D90-1 (APH+)

Always

Below 1 Ω

D89-3 (APHG) - Body ground

Always

Below 1 Ω

D90-3 (APHG) - Body ground

Always

Below 1 Ω

AI HTR relay terminal 3 or D89-1 (APH+) - Body ground

Always

10 kΩ or higher

AI HTR relay terminal 3 or D90-1 (APH+) - Body ground

Always

10 kΩ or higher

(d) Reinstall the air pump heater (AI HTR) relay.

(e) Reconnect the air pump assembly (for bank 1 or bank 2) connector.

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

7.

INSPECT AIR PUMP ASSEMBLY (FOR BANK 1 OR BANK 2)

(a) Inspect the air pump assembly (for bank 1 or bank 2) (See page ).

NG

REPLACE AIR PUMP ASSEMBLY (FOR BANK 1 OR BANK 2)

OK

8.

PERFORM ACTIVE TEST USING TECHSTREAM (SECONDARY AIR INJECTION SYSTEM OPERATION)

(a) Visual check:

(1) Start the engine and warm it up.

(2) Turn the ignition switch off.

(3) Disconnect the No. 1 air hose.

(4) Connect the Techstream to the DLC3.

(5) Turn the ignition switch to ON.

(6) Turn the Techstream on.

(7) 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.

(8) Start the engine.

(9) Perform the AIR system forced operation while the engine is idling.

(10) Place your hand near the air switching valve port and check that the exhaust gas pressure pulsates when the ASV is turned ON.

CAUTION:

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

(11) 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.

(12) Check that the exhaust gas does not pulsate when the ASV is turned OFF.

(13) Turn the ignition switch off.

NOTICE:

  • 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 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.

OK:

Air Pump Operation

ASV Operation

Exhaust Gas Pulsation

ON

OFF

Not detected

ON

ON

Detected

(b) 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.

(5) 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 and AIR PUMP 1: OFF, ASV1: CLOSE, AIR PUMP 2: OFF, ASV2: CLOSE.

(7) Start the engine after the Techstream initialization is finished.

(8) Perform the AIR system forced operation while the engine is idling.

(9) 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.

(10) Turn the ignition switch off.

OK:

AIR System Operation

Pulsation Condition

(ECM Calculation)

Air-Fuel Ratio

(Reference)

AIR PUMP: ON, ASV: OPEN

18 kPa or more

18 or more

AIR PUMP: OFF, ASV: CLOSE

Less than 25 kPa

Approximately 14.5

(around stoichiometric air-fuel ratio)

Reference:

If the air pump operation is confirmed as normal (See page ), the air-fuel ratio detected in front of the 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

B

GO TO STEP 16

A

9.

INSPECT AIR TUBE (BLOCKAGE AND LEAK)

(a) Check that the No. 2 and No. 3 air tubes are securely connected to both the exhaust manifold and the air switching valve assembly.

(b) Inspect the air tube for blockages and damage.

OK:

No blockages in or damage to air tubes.

NG

REPLACE AIR TUBE

OK

10.

INSPECT AIR SWITCHING VALVE ASSEMBLY (FOR BANK 1 OR BANK 2)

(a) Inspect the air switching valve (for bank 1) (See page ).

(b) Inspect the air switching valve (for bank 2) (See page ).

Result

Result

Proceed to

OK

A

NG (for Bank 1)

B

NG (for Bank 2)

C

B

REPLACE AIR SWITCHING VALVE ASSEMBLY (FOR BANK 1)

C

REPLACE AIR SWITCHING VALVE ASSEMBLY (FOR BANK 2)

A

11.

INSPECT AIR INJECTION CONTROL DRIVER (POWER SOURCE OF AIR INJECTION CONTROL DRIVER)

(a) Disconnect the air injection control driver (AID) (for bank 1 or bank 2) connectors.

(b) Turn the ignition switch to ON.

(c) Measure the voltage according to the value(s) in the table below.

Standard Voltage:

Tester Connection

Switch Condition

Specified Condition

D48-1 (BATT) - Body ground

Always

11 to 14 V (near battery voltage)

D50-5 (+B) - Body ground

Ignition switch ON

11 to 14 V (near battery voltage)

D52-1 (BAT2) - Body ground

Always

11 to 14 V (near battery voltage)

D54-5 (+B2) - Body ground

Ignition switch ON

11 to 14 V (near battery voltage)

(d) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection

Condition

Specified Condition

D50-1 (E) - Body ground

Always

Below 1 Ω

D54-1 (E2) - Body ground

Always

Below 1 Ω

NG

REPAIR OR REPLACE AIR INJECTION CONTROL DRIVER POWER SOURCE CIRCUIT

OK

12.

CHECK HARNESS AND CONNECTOR (ECM - AIR INJECTION CONTROL DRIVER)

(a) Disconnect the ECM connectors.

(b) Disconnect the air injection control driver (AID) (for bank 1 or bank 2) connectors.

(c) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection

Condition

Specified Condition

D74-28 (AIRV) - D50-3 (SIV)

Always

Below 1 Ω

A24-43 (ARV2) - D54-3 (SIV2)

Always

Below 1 Ω

D74-28 (AIRV) or D50-3 (SIV) - Body ground

Always

10 kΩ or higher

A24-43 (ARV2) or D54-3 (SIV2) - Body ground

Always

10 kΩ or higher

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

13.

PERFORM ACTIVE TEST USING TECHSTREAM

(a) Disconnect the air injection control driver (AID) (for bank 1 or bank 2) connector.

(b) Connect terminals DI and SIV or DI2 and SIV2 of the wire harness connector for the AID.

(c) Connect the Techstream to the DLC3.

(d) Turn the ignition switch to ON and turn the Techstream on.

(e) 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.

(f) Start the engine.

(g) Perform the AIR system forced operation while the engine is idling.

(h) 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.

(i) Turn the ignition switch off.

NOTICE:

  • 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

D50-3 (SIV) - D50-1 (E)

AIR PUMP: ON, ASV: OPEN

0.5 to 2 V

D54-3 (SIV2) - D54-1 (E2)

AIR PUMP: ON, ASV: OPEN

0.5 to 2 V

D50-3 (SIV) - D50-1 (E)

AIR PUMP: OFF, ASV: CLOSE

11 to 14 V

D54-3 (SIV2) - D54-1 (E2)

AIR PUMP: OFF, ASV: CLOSE

11 to 14 V

(j) Connect terminals DI and SIP or DI2 and SIP2 of the wire harness connector for the AID.

(k) Connect the Techstream to the DLC3.

(l) Turn the ignition switch to ON and turn the Techstream on.

(m) 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.

(n) Start the engine.

(o) Perform the AIR system forced operation while the engine is idling.

(p) 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.

(q) Turn the ignition switch off.

NOTICE:

  • 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

D50-4 (SIP) - D50-1 (E)

AIR PUMP: ON, ASV: OPEN

0.5 to 2 V

D54-4 (SIP2) - D54-1 (E2)

AIR PUMP: ON, ASV: OPEN

0.5 to 2 V

D50-4 (SIP) - D50-1 (E)

AIR PUMP: OFF, ASV: CLOSE

11 to 14 V

D54-4 (SIP2) - D54-1 (E2)

AIR PUMP: OFF, ASV: CLOSE

11 to 14 V

NG

REPLACE ECM

OK

14.

REPLACE AIR INJECTION CONTROL DRIVER (FOR BANK 1 OR BANK 2)

(a) Replace the air injection control driver (for bank 1 or bank 2) (See page ).

NEXT

15.

CHECK WHETHER DTC OUTPUT RECURS (DTC P2440, P2441, P2442 AND/OR P2443)

(a) Start the engine and warm it up.

(b) Turn the ignition switch off.

(c) Connect the Techstream to the DLC3.

(d) Turn the ignition switch to ON.

(e) Turn the Techstream on.

(f) Clear DTCs (if set) (See page ).

(g) Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Automatic Mode.

(h) Start the engine after the Techstream initialization is finished.

(i) Perform the System Check operation by pressing ENTER (Next).

(j) After operating the AIR system, perform the following to confirm the AIR system pending codes: Press the Exit button.

(k) Check pending DTCs.

(l) Turn the ignition switch off.

OK:

No pending DTC output.

NOTICE:

  • 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.
OK

END

NG

REPLACE ECM

16.

INSPECT VACUUM HOSES (AIR SWITCHING VALVE - PRESSURE SENSOR)

OK:

No blockage and no deformation in vacuum hose.

NG

REPAIR OR REPLACE VACUUM HOSE

OK

17.

INSPECT AIR SWITCHING VALVE ASSEMBLY (PRESSURE SENSOR)

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) Turn the Techstream on.

(d) Enter the following menus: Powertrain / Engine and ECT / Data List / Air pump pressure (Absolute) and Air Pump2 Pressure (Absolute).

(e) Check the pressure displayed on the Techstream.

Standard pressure:

45 to 135 kPa

HINT:

The Techstream displays the air pump pressure as absolute pressure.

Result

Result

Proceed to

OK

A

NG (for Bank 1)

B

NG (for Bank 2)

C

A

CHECK FOR INTERMITTENT PROBLEMS

B

REPLACE AIR SWITCHING VALVE ASSEMBLY (FOR BANK 1)

C

REPLACE AIR SWITCHING VALVE ASSEMBLY (FOR BANK 2)

    Secondary Air Injection System Air Flow / Pressure Sensor Circuit Range / Performance Bank1 (P2431-P2433,P2436-P2438)

    Secondary Air Injection System Pump Stuck On Bank1 (P2444-P2447)

    See More:

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