T-SB-0333-17

T-SB-0333-17
December 12, 2017
Air Injection System - Moisture Intrusion: MIL "ON" DTC
P2440/P2442
Service
Category
Engine/Hybrid System
Section
Emission Control
Market USA
Applicability
YEAR(S)
MODEL(S)
ADDITIONAL INFORMATION
2012
Tacoma
WMI(s): 3TM, 5TF
Body Type(s): Regular Cab, Access Cab, Extra
Cab
Transmission(s): MANUAL, AUTOMATIC
Plant Code(s): -
Introduction
Some 2012 model year Tacoma vehicles equipped with the 1GR-FE engine may exhibit a
MIL “ON” condition with Diagnostic Trouble Codes (DTCs) P2440/P2442 (Secondary Air Injection
System Switching Valve Stuck Open Bank 1/Bank 2). This condition may be caused by moisture
intrusion into the air injection pump. Follow the Repair Procedure in this bulletin to address
this condition.
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
EG1709
R & R Air Pump Assembly,
Emission Control Valve Set, and Gaskets,
Install Air Pump Cover
0.6
17600-0P040
8A
99
APPLICABLE WARRANTY
 This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months
or 36,000 miles, whichever occurs first, from the vehicle’s in-service date.
 For California specification 2012 model year vehicles sold, registered, and operated in Arizona,
California, Connecticut, Maine, Maryland, Massachusetts, New Jersey, Oregon, Pennsylvania,
Rhode Island, Washington, and Vermont, this repair may be covered depe nding on vehicle
model year, under the California Emission Warranty, which is in effect for 36 months or
50,000 miles, whichever occurs first, from the vehicle ’s in-service date.
 Warranty application is limited to occurrence of the specified condition described in
this bulletin.
© 2017 Toyota Motor Sales, USA
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T-SB-0333-17
December 12, 2017
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Air Injection System - Moisture Intrusion: MIL "ON" DTC P2440/P2442
Parts Information
PART NUMBER
PART NAME
QTY
25710-31022
Valve Assy, Air Switching
1
17613-0P010
Cover, Air Pump
1
17610-0W020
Pump Assy, Air
1
17376-50010
Gasket, Air Tube
2
17377-31010
Gasket, Air Tube, No. 2
2
PREVIOUS
NEW
25710-31021
N/A
NOTE
 If evidence of water/moisture intrusion is present in the air injection pump and/or air switching
valves, it is imperative that the air pump and the air switching valves are replaced.
 ALL parts listed in this bulletin MUST be re placed to ensure the condition is properly addressed.
Failure to replace ALL parts may result in comeback repairs.
Required Tools & Equipment
REQUIRED EQUIPMENT
SUPPLIER
Techstream 2.0*
Techstream Lite
PART NUMBER
QTY
TS2UNIT
ADE
Techstream Lite (Green Cable)
TSLITEPDLR01
1
TSLP2DLR01
* Essential SST.
NOTE
 ONLY ONE of the Techstream units listed above is required.
 Software version 12.20.024 or later is required.
 Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)
at 1-800-368-6787.
Repair Procedure
1. Using Techstream, perform a Health Check.
Are either of the following DTCs present?
P2440/P2442 (Secondary Air Injection System Switching Valve Stuck Open Bank 1/Bank 2).

YES — Continue to step 2.

NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
© 2017 Toyota Motor Sales, USA
T-SB-0333-17
December 12, 2017
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Air Injection System - Moisture Intrusion: MIL "ON" DTC P2440/P2442
Repair Procedure (Continued)
2. Start the engine and warm it up to operating temperature, then turn the ignition switch OFF.
3. Disconnect the air injection control
driver connector.
Figure 1.
B
A
4. Connect terminals D1 and SIV of the wire
harness connector for the air injection
control driver.
C
A
Air Injection Control Driver
B
ECM
C
Front View of Wire Harness Connector
5. Connect Techstream to the DLC3.
6. Turn the ignition switch and Techstream ON.
7. Enter the following menus: Powertrain – Engine and ECT – Utility – Secondary Air Injection
Check – Manual Mode – AIR PUMP: ON, ASV 1: Open, 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.
8. Start the engine.
9. Perform secondary air injection system forced operation while the engine is idling.
© 2017 Toyota Motor Sales, USA
T-SB-0333-17
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Air Injection System - Moisture Intrusion: MIL "ON" DTC P2440/P2442
Repair Procedure (Continued)
10. Measure the voltage between the SIV and E terminals of the ECM connector when the
secondary air injection system is ON and OFF.
NOTICE
 Performing the 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 7 minutes with the ignition switch ON or the engine running.
 Turn the ignition switch OFF when the Secondary Air Injection Check operation completes.
TESTER CONNECTION
CONDITION
SPECIFIED CONDITION
A7-3 (SIV) - A7-1 (E)
AIR PUMP: ON, ASV: OPEN
0.5V to 2V
A7-3 (SIV) - A7-1 (E)
AIR PUMP: OFF, ASV: CLOSE
11V to 14V
11. Is voltage present at the pump?
 YES — Continue to step 12.

NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
12. Did the air pressure (gauge) value increase from 0 to 1 psi on Techstream while the pump
was running during the test?


YES — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
NO — Continue to step 13.
13. Remove the air pump assembly for inspection.
Refer to the Technical Information System (TIS), applicable model and model year
Repair Manual:

2012 Tacoma:
Engine/Hybrid System – Engine Control – “1GR-FE Emission Control:
Air Pump (w/ Secondary Air Injection System: Removal”
14. With the pump removed from the vehicle, verify if there is liquid or evidence of liquid entering
the pump.
Is there liquid or evidence of liquid entering the pump?


YES — Continue to step 15.
NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
© 2017 Toyota Motor Sales, USA
T-SB-0333-17
December 12, 2017
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Air Injection System - Moisture Intrusion: MIL "ON" DTC P2440/P2442
Repair Procedure (Continued)
15. Replace the following air injection system components to ensure reliability:
 Air pump
 Air pump cover
 Air switching valve
 Air switching valve gaskets
Refer to TIS, applicable model and model year Repair Manual:

2012 Tacoma:
Engine/Hybrid System – Engine Control – “1GR-FE Emission Control:
Air Pump (w/ Secondary Air Injection System: Installation”

2012 Tacoma:
Engine/Hybrid System – Engine Control – “1GR-FE Emission Control:
Air Switching Valve (w/ Secondary Air Injection System): Removal / Installation”
NOTICE
To prevent the possibility of water intrusion in the
future, install the air pump cover. To install the air pump
cover, place the cover over the air pump, making sure to
follow the contours of the air pump. Then, apply downward
pressure until a click is heard. Confirm the air pump
cover is fully seated when complete.
16. Clear the DTCs and test drive the vehicle to confirm the condition has been addressed.
© 2017 Toyota Motor Sales, USA