Toyota Tundra Service Manual: Secondary Air Injection System Pump Stuck On Bank1 (P2444-P2447)

Toyota Tundra Service Manual / Engine, Hybrid System / 1ur-fe Engine Control / Sfi System / Secondary Air Injection System Pump Stuck On Bank1 (P2444-P2447)

DESCRIPTION

Refer to P2440 (See page ).

DTC No.

DTC Detection Condition

Trouble Area

P2444

P2446

Secondary air pressure more than 3.0 kPa (23 mmHg) despite ECM commanding air pump to turn off

(2 trip detection logic)

  • Short in air pump circuit
  • Open or short in pressure sensor circuit
  • Pressure sensor (Air switching valve assembly)
  • Air injection control driver (AID)
  • ECM

P2445

P2447

Secondary air pressure less than 1.9 kPa (14 mmHg) despite ECM commanding air pump to turn on

(2 trip detection logic)

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

When secondary air injection is on, the amount of air from the air pump is below the threshold

(2 trip detection logic)

MONITOR DESCRIPTION

The ECM monitors the pressure in the secondary air passage using the pressure sensor located on the Air Switching Valve (ASV) of the Secondary Air Injection (AIR) system. The sensor measures the pressure in the secondary air passage and transmits a signal to the ECM.

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:

  • The pressure indicated by the pressure sensor does not reach threshold levels despite the ECM turning on the air pump.
  • The pressure indicated by the pressure sensor exceeds threshold levels despite the ECM turning off the air pump.

MONITOR STRATEGY

Related DTCs

P2444: Air pump stuck ON

P2445: Air pump stuck OFF

P2446: Air pump stuck ON

P2447: Air pump stuck OFF

Required Sensors/Components (Main)

Pressure sensor

Required Sensors/Components (Related)

-

Frequency of Operation

Once per drive cycle

Duration

7 seconds

MIL Operation

2 driving cycles

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)

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

P2445, P2447 AIR insufficient

Battery voltage

11 V or higher

Atmospheric pressure

45 kPa (338 mmHg) or higher

Engine

Running

Air flow pattern check condition during AIR monitor during AIR: ON*

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

*: Air flow pattern check condition during AIR monitor during AIR: ON

-

AIR valve

Open

Time after secondary air injection in operation

1 second 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

P2444, P2446 AIR pump is stuck ON

Either condition is met

(a) or (b)

(a) AIR OFF Condition 1

Met

(b) AIR OFF Condition 3

Met

P2445, P2447 AIR pump is stuck OFF

Either condition is met

(a) or (b)

(a) AIR ON Condition 2

Met

(b) AIR ON Condition 4

Met

P2445, P2447 AIR insufficient

Either condition is met

(a) or (b)

(a) Air flow value at Bank 1 or Bank 2

160 L/min. or less

(b) Air flow value at Bank 1 and Bank 2

160 L/min. or less

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: P2444, P2445, P2446 or P2447.
  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

ASV 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

ASV stuck closed

P2441

or

P2443

Case 1

Case 5

ASV stuck open and air pump stuck ON

P2440 and P2444

or

P2442 and P2446

Case 2

Case 6

ASV stuck open and air pump stuck OFF

P2440 and P2445

or

P2442 and P2447

Case 3

Case 7

ASV stuck closed and air pump stuck ON

P2441 and P2444

or

P2443 and P2446

Case 4

Case 8

ASV 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 DTC P2444, P2445, P2446 AND/OR P2447)

(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

P2444, P2445, P2446 and/or P2447 is output

A

P2444, P2445, P2446 and/or P2447 and P0418 and/or P0419 are output

B

P2444, P2445, P2446 and/or P2447 and other DTCs (except P0418 and P0419) are output

C

If any DTCs other than P0418, P0419, P2444, P2445, P2446 and/or P2447 are output, troubleshoot those DTCs first.

B

GO TO AIR PUMP INSPECTION PROCEDURE

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 - AIR PUMP HEATER RELAY, BODY GROUND)

(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 relay (AI HTR).

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

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

7.

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

(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) 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.

(g) Start the engine.

(h) Perform the AIR system intrusive operation while the engine is idling.

(i) 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*

AIR PUMP: ON, ASV: OPEN

ON

ON

1.9 kPa or more

AIR PUMP: OFF, ASV: CLOSE

OFF

OFF

Less than 3.0 kPa

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

(j) 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.
NG

GO TO STEP 9

OK

8.

CHECK WHETHER DTC OUTPUT RECURS (DTC P2444, P2445, P2446 AND/OR P2447)

(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.

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.
Result

Result

Proceed to

P2444, P2445, P2446 and/or P2447 is output

A

No pending DTC is output

B

B

CHECK FOR INTERMITTENT PROBLEMS

A

9.

CHECK VACUUM HOSE (PRESSURE SENSOR - AIR SWITCHING VALVE)

(a) Check the vacuum hose connections with the pressure sensor and air switching valve assembly.

(b) Inspect the vacuum hose for blockages and damage.

OK:

Vacuum hose has no blockages or damage.

NG

REPAIR OR REPLACE VACUUM HOSE

OK

10.

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

B

REPLACE AIR SWITCHING VALVE ASSEMBLY (FOR BANK 1)

C

REPLACE AIR SWITCHING VALVE ASSEMBLY (FOR BANK 2)

A

11.

CHECK AIR INJECTION SYSTEM PIPE CONNECTIONS

(a) Check that all the pipes and hoses between the air pump and ASV are securely connected.

(b) Inspect the pipes and hoses for blockages and damage.

OK:

AIR system piping has no blockages or damage.

NG

REPAIR OR REPLACE SECONDARY AIR INJECTION SYSTEM PIPING

OK

12.

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

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

(b) 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

(c) Turn the ignition switch to ON.

(d) 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)

NG

REPAIR OR REPLACE AIR INJECTION CONTROL DRIVER POWER SOURCE CIRCUIT

OK

13.

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

(a) Disconnect the ECM connector.

(b) Disconnect the air injection control driver (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

D74-54 (AIRP) - D50-4 (SIP)

Always

Below 1 Ω

D74-53 (ARP2) - D54-4 (SIP2)

Always

Below 1 Ω

D74-54 (AIRP) or D50-4 (SIP) - Body ground

Always

10 kΩ or higher

D74-53 (ARP2) or D54-4 (SIP2) - Body ground

Always

10 kΩ or higher

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

14.

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

(a) Start the engine and warm it up.

(b) Turn the ignition switch off.

(c) Connect the 400 A probe of an ammeter to the (+) wire of the air pump.

(d) Connect the Techstream to the DLC3.

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

(f) Start the engine.

(g) 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.

(h) Measure the current while the air pump is on and off.

Standard Current:

Tester Operation

Air Pump

ASV

Specified Condition

AIR PUMP: ON, ASV: OPEN

ON

OPEN

10 to 40 A

AIR PUMP: OFF, ASV: CLOSE

OFF

CLOSE

Below 1 A

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

GO TO STEP 17

NG

15.

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

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

NEXT

16.

CHECK WHETHER DTC OUTPUT RECURS (DTC P2444, P2445, P2446 AND/OR P2447)

(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.

OK:

No pending DTC is output.

(l) Turn the ignition switch off.

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

17.

PERFORM ACTIVE TEST USING TECHSTREAM

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

(b) Connect terminals DI and SIV or DI2 and SIV2 of the wire harness connector for the air injection control driver (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 air injection control driver.

(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

18.

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

19.

CHECK WHETHER DTC OUTPUT RECURS (DTC P2444, P2445, P2446 AND/OR P2447)

(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.

OK:

No pending DTC is output.

(l) Turn the ignition switch off.

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

20.

PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE EGR STEP POSITION)

(a) Connect the Techstream to the DLC3.

(b) Start the engine and warm it up until the engine coolant temperature reaches 75°C (167°F) or higher.

HINT:

  • When performing the Active Test, make sure the shift lever is in P or N.
  • The A/C switch and all accessory switches should be off.

(c) Turn the Techstream on.

(d) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the EGR Step Position.

(e) Confirm the Throttle Idle Position is ON and check the engine idling condition and MAP values in the Data List while performing the Active Test.

HINT:

  • Do not leave the EGR valve open for 10 seconds or more during the Active Test.
  • Be sure to return the EGR valve to step 0 when the Active Test is completed.

OK:

MAP and idling condition change in response to EGR step position as follows.

Standard:

-

EGR Step Position (Active Test)

0 Steps

0 to 30 Steps

Idling condition

Steady idling

Idling changes from steady to rough idling or engine stall

MAP

(Data List)

20 to 40 kPa (150 to 300 mmHg)

MAP value is at least +10 kPa (75 mmHg) higher than when EGR valve is fully closed

OK

REPLACE ECM

NG

21.

INSPECT EGR VALVE ASSEMBLY

(a) Remove the EGR valve assembly (See page ).

(b) Check if the EGR valve is stuck open.

OK:

EGR valve is tightly closed.

HINT:

Perform "Inspection After Repair" after repairing or replacing the EGR valve assembly (See page ).

OK

REPLACE ECM

NG

REPLACE EGR VALVE ASSEMBLY

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