Secondary Air Injection System - Water Intrusion: MIL "ON" DTC P0418, P0419, And/or P244#

T-SB-0160-11 Rev2 October 17, 2011
Secondary Air Injection System - Water Intrusion: MIL

"ON" DTC P0418, P0419, and/or P244#
Service
Category Engine/Hybrid System
Section Engine Control Market USA
Applicability
YEAR(S) MODEL(S) ADDITIONAL INFORMATION
2008 – 2011 Sequoia
2007 – 2011 Tundra
REVISION NOTICE
July 12, 2012 Rev2:
• The Warranty Information, Parts Information, and Repair Procedure sections have been
updated.
February 9, 2012 Rev1:
• The Introduction, Warranty Information, Parts Information, and Repair Procedure sections
have all been updated.
Any previous printed versions of this bulletin should be discarded.
SUPERSESSION NOTICE
The information contained in this bulletin supersedes SB Nos. T-SB-0329-08 and T-SB-0350-09.
• Applicability has been updated to include 2009 – 2011 model year Sequoia and Tundra vehicles.
• The air pump inlet has been updated to prevent water intrusion.
SB Nos. T-SB-0329-08 and T-SB-0350-09 are Obsolete and any printed versions should be
discarded. Be sure to review the entire content of this bulletin before proceeding.
Introduction
Some 2008 – 2011 model year Sequoia and 2007 – 2011 model year Tundra vehicles may exhibit a
MIL “ON” condition with the following Diagnostic Trouble Codes (DTCs):
• P0418/P0419: Secondary Air Injection System Control “A/B” Circuit
• P2440/P2442: Secondary Air Injection System Switching Valve Stuck Open Bank 1/Bank 2
• P2441/P2443: Secondary Air Injection System Switching Valve Stuck Closed Bank 1/Bank 2
© 2012 Toyota Motor Sales, USA Page 1 of 12

T-SB-0160-11 Rev2 October 17, 2011 Page 2 of 12
Secondary Air Injection System - Water Intrusion: MIL "ON" DTC P0418, P0419,
and/or P244#
Introduction (Continued)
• P2445/P2447: Secondary Air Injection System Pump Stuck Off Bank 1/Bank 2
This condition may be caused by water intrusion into the air injection pump assemblies. Use the
following procedure to address this condition.
Warranty Information
OP CODE DESCRIPTION MODEL ENGINE TIME OFP T1 T2
1GR-FE
(until ’10 MY)
Sequoia, 1UR-FE
R & R Air Pump Inlet, 4.0 17610-0S010
Tundra
EG9024 Air Pump Assembly, and 2UZ-FE 8A 99
Emission Control Valve Set
3UR-FE/FBE
1GR-FE
Tundra 4.0 17610-0P010
(from ’11 MY)
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 vehicles sold, registered, and operated in California, Connecticut
(starting with ’08 MY), Maine, Maryland (starting with ’11 MY), Massachusetts, New Jersey
(starting with ’09 MY), New Mexico (’11 MY only), Oregon (starting with ’09 MY), Pennsylvania
(starting with ’08 MY), Rhode Island (starting with ’08 MY), Vermont, and Washington (starting
with ’09 MY), this repair is covered under the California Emission Warranty. This warranty is in
effect for 84 months or 70,000 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.
Required Tools & Equipment
REQUIRED EQUIPMENT SUPPLIER PART NUMBER QTY
TIS Techstream*
or TSPKG1
Techstream Lite ADE or 1
TSLITEDLR01
NOTE: Software version 7.10.030 or later is required.
* Essential SST.
NOTE
Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE) at
1-800-368-6787.
© 2012 Toyota Motor Sales, USA

and/or P244#
Parts Information
ENGINE PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY
1GR-FE
2
( –8/08)*
2UZ-FE
N/A 90467-28007 Clamp 1
( –8/08)*
3UR-FE
2
( –8/08)*
1GR-FE
17610-0S010 Same 2
(11/06–10/10)*
1GR-FE
17610-0P010 Same 1
(10/10– )*
1UR-FE Pump Assembly, Air 2
2UZ-FE 1
17610-0S010 Same
3UR-FE 2
3UR-FBE 2
1GR-FE
25710-31010 25710-31011 1
(11/06–10/10)*
1GR-FE 25701-31010 25701-31011 1

(10/10–05/11)* 25702-31010 25702-31011 1
1GR-FE 25701-31011 Same 1

(05/11– )* 25702-31011 Same 1
25701-38100 Same 1
1UR-FE Valve Set, Emission Control
25702-38050 Same 1
2UZ-FE
25710-50030 25710-50031 2
(11/06–4/07)*
2UZ-FE 25710-50030 25710-50031 1

(5/07–4/09)* 25710-50040 25710-50041 1
3UR-FE
25701-38060 25701-38061 1
3UR-FBE
1GR-FE
1UR-FE
17621-0S011 17621-0S012 Air Pump Inlet 1
3UR-FE
3UR-FBE
2UZ-FE N/A 04001-7310F Air Inlet Cover Kit 1

and/or P244#
Parts Information (Continued)
ENGINE PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY
1GR-FE 17376-50010 Same 2

(11/06–10/10)* 17377-31010 Same 2
1GR-FE
17377-38010 Same 4
(10/10– )*
17376-38030 Same 2
1UR-FE
17377-38010 Same 2
Gasket, Air Tube
2UZ-FE 17376-50010 Same 2
(11/06–04/09)* 17377-50010 Same 2
3UR-FE
17377-38010 Same 2
3UR-FBE
3UR-FE
17376-38020 Same 2
3UR-FBE
3UR-FE 17171-0S030 Same 2
Gasket, Intake Manifold
3UR-FBE 17171-0S020 Same 2
* MM/YY.
NOTE
• For 1GR/1UR/3UR Vehicles: If moisture/water is found to be present in the Air Injection
Pumps and/or Air Switching Valves, it is imperative that ALL air pumps AND the emission
control valves are replaced. All parts listed for the applicable model in this bulletin must be
replaced in order to ensure the condition is properly addressed. Failure to replace all parts
may result in comeback repairs.
• For 2UZ Vehicles: Most vehicles will NOT require the replacement of the Bank 1 Air Pump. If
replacement is necessary, a vehicle health check must be attached to the R.O. showing the
vehicle has one of the following DTCs: P2444, P2445, or P0418. Inappropriate replacement of
the Bank 1 Air Pump on 2UZ-FE vehicles will result in a warranty claim debit.

and/or P244#
Repair Procedure
1. Using TIS Techstream, check if DTCs P0418, P0419, P2440, P2441, P2442, P2443, P2445,
and/or P2447 are present.
2. Using TIS Techstream, perform the manual Air Injection Active Test (options 1 and 2) to verify if
the signal from the air injection control driver is reaching the air pumps.
The pumps should be heard turning on at this point and there should be battery voltage on pin 2
of the pumps during this test. If there is NO voltage, refer to Service Bulletin T-SB-0029-08, “Air
Injection Control Driver” for control driver diagnostic procedures.
3. If during the test, voltage is present at the pump and the pump is NOT running, or the Air
Pressure (gauge) value did NOT increase from 0 to 1 psi on TIS Techstream with the pump
running, remove the air pump assemblies for inspection.
Refer to the Technical Information System (TIS), applicable model and model year Repair
Manual:
2008 – 2011 Sequoia:
Engine/Hybrid System – Emission Control – “3UR-FE / 3UR-FBE / 2UZ-FE / 1UR-FE Emission
Control: Air Pump: Removal”
• 2008 Sequoia: 3UR-FE / 2UZ-FE (Bank 2)
• 2009 Sequoia: 3UR-FE / 3UR-FBE / 2UZ-FE (Bank 2)
• 2010 Sequoia: 3UR-FE / 3UR-FBE / 1UR-FE
2007 – 2011 Tundra:
Engine/Hybrid System – Emission Control – “3UR-FE / 3UR-FBE / 2UZ-FE / 1GR-FE / 1UR-FE
Emission Control: Air Pump: Removal”
• 2007 Tundra: 3UR-FE / 2UZ-FE (Bank 2) / 1GR-FE
• 2009 Tundra: 3UR-FE / 3UR-FBE / 2UZ-FE (Bank 2) / 1GR-FE
• 2010 Tundra: 3UR-FE / 3UR-FBE / 1GR-FE / 1UR-FE
4. With the pumps removed from the vehicle, verify if there is liquid or evidence that liquid entered
the pumps.
• YES — If there is liquid evidence, go to step 5.
• NO — If there is NO evidence of liquid, go to step 7.

and/or P244#
Repair Procedure (Continued)
5. If liquid evidence is present, follow the steps below.

A. Replace the air pump inlet.
B. Install the inlet cover (2UZ-FE only).
C. Replace all air pumps under the fender well.
D. Install clamps on the inlet pipe to air pump hose joint where not currently installed, as shown
in Figures 2 and 3.
NOTE
ONLY install clamps on vehicles where they are not currently installed. If already present,
reuse the currently installed clamps.
FOR 2UZ-FE EQUIPPED VEHICLES
• ONLY replace the Bank 2 pump.
• Install the foam seal to the top of the air inlet along the inlet’s edge and then attach the
cover with zip ties as shown below. The zip tie length should be a minimum of 2.5 in.
(64 mm) in length when tightened.
Figure 1.
2
1
1 Foam Seal 3 Air Inlet — Located Above RH Front Wheel

2 Cover 4 Zip Ties

and/or P244#
Refer to TIS, applicable model and model year Repair Manual:

2008 – 2011 Sequoia:
Engine/Hybrid System – Emission Control – “3UR-FE / 3UR-FBE / 2UZ-FE / 1UR-FE Emission
Control: Air Pump: Installation”
• 2008 Sequoia: 3UR-FE / 2UZ-FE (Bank 2)
• 2009 Sequoia: 3UR-FE / 3UR-FBE / 2UZ-FE (Bank 2)
2007 – 2011 Tundra:
Engine/Hybrid System – Emission Control – “3UR-FE / 3UR-FBE / 2UZ-FE / 1GR-FE / 1UR-FE
Emission Control: Air Pump: Installation”
• 2009 Tundra: 3UR-FE / 3UR-FBE / 2UZ-FE (Bank 2) / 1GR-FE
IMPORTANT
Make sure the clamp orientation is as shown in Figures 2 and 3.

and/or P244#

Figure 2. 1GR-FE/3UR-FE/1UR-FE Air Injection Pump Assembly (with clamps)
1
4
1
6
2
5
3
9 10 11
12
1 Clamp 1 Installation Orientation 7 LH

2 Clamp 2 Installation Orientation 8 Hose Stopper Must Remain Within Clip Tabs
3 Clamp Installation Location (Typical) 9 Air Pump
4 ◦ 10 Air Hose
90
5 Upper 11 Inlet
6 RH 12 Approximately 0 – 5 mm (0 – 0.2 in.)

and/or P244#

Figure 3. 2UZ-FE Air Injection Pump Assembly (with clamps)
5 6 7
1 Clamp Installation Orientation 5 Air Pump

2 Clamp Installation Location 6 Air Hose
3 Upper 7 Inlet
4 Hose Stopper Must Remain Within Clip Tabs 8 Approximately 0 – 5 mm (0 – 0.2 in.)

and/or P244#
6. In some instances where water may have entered the system, DTCs P2440/P2441/P2442/P2443
may set. Replacement of the emission control valves is necessary to ensure reliability.
Refer to TIS, applicable model and model year Repair Manual to replace the emission control
valves:
2008 – 2011 Sequoia:
Engine/Hybrid System – Engine Control – “3UR-FE / 3UR-FBE / 2UZ-FE / 1UR-FE Engine
Control System: SFI System: P2440–P2443 Secondary Air Injection System Switching Valve
Stuck Bank 1”
• 2008 Sequoia: 3UR-FE / 2UZ-FE
• 2009 Sequoia: 3UR-FE / 3UR-FBE / 2UZ-FE
2007 – 2011 Tundra:
Engine/Hybrid System – Engine Control – “3UR-FE / 2UZ-FE / 1GR-FE / 1UR-FE Engine
Control System: SFI System: P2440–P2443 Secondary Air Injection System Switching Valve
Stuck Bank 1”
• 2007 Tundra: 3UR-FE / 2UZ-FE / 1GR-FE
• 2009 Tundra: 3UR-FE / 3UR-FBE / 2UZ-FE / 1GR-FE
7. If there is NO liquid found in the air pump assemblies, or the DTCs are still present after
replacement, inspect the air injection system.
Refer to TIS, applicable model and model year Repair Manual:
2008 – 2011 Sequoia:
• P0412/P0415:
Control: SFI System: P0412: Secondary Air Injection System Control A Circuit” (P0415:
Secondary Air Injection System Switching Valve “B” Circuit)

and/or P244#
• P0418/P0419:
Control: SFI System: P0418: Secondary Air Injection System Control A Circuit” (P0419:
Secondary Air Injection System Control “B” Circuit)
• P2440 – P2443:
Engine/Hybrid System – Engine Control – “3UR-FE / 3UR-FBE / 2UZ-FE / 1UR-FE
Engine Control: SFI System: P2440–P2443 Secondary Air Injection System Switching
Valve Stuck Bank 1”
• P2445/P2447:
Control: SFI System: P2444–P2447: Secondary Air Injection System Pump Stuck On Bank
1” (P2445: Secondary Air Injection System Pump Stuck Off Bank 1, P2447: Secondary Air
Injection System Pump Stuck Off Bank 2)
2007 – 2011 Tundra:
• P0412/P0415:
Engine/Hybrid System – Engine Control – “3UR-FE / 3UR-FBE / 2UZ-FE / 1GR-FE / 1UR-FE
Engine Control System: SFI System: P0412: Secondary Air Injection System Switching
Valve A Circuit” (P0415: Secondary Air Injection System Switching Valve “B” Circuit)

and/or P244#

• P0418/P0419:
Control System: SFI System: P0418: Secondary Air Injection System Control A Circuit”
(P0419: Secondary Air Injection System Control “B” Circuit)
• P2440 – P2443:
Engine/Hybrid System – Engine Control – “3UR-FE / 3UR-FBE / 2UZ-FE / 1GR-FE
/ 1UR-FE Engine Control System: SFI System: P2440–P2443 Secondary Air Injection
System Switching Valve Stuck Bank 1”
• P2445/P2447:
Control System: SFI System: P2444–P2447: Secondary Air Injection System Pump Stuck
On Bank 1” (P2445: Secondary Air Injection System Pump Stuck Off Bank 1, P2447:
Secondary Air Injection System Pump Stuck Off Bank 2)
8. Clear the DTC(s) and road test the vehicle to confirm the condition has been corrected.

Secondary Air Injection System - Water Intrusion: MIL "ON" DTC P0418, P0419, And/or P244#

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What are some of the diagnostic trouble codes (DTCs) that may exhibit this condition?

What are some of the diagnostic trouble codes (DTCs) that may exhibit this condition?

What engine models and years could exhibit this condition?

What engine models and years could exhibit this condition?

T-SB-0160-11 Rev2 October 17, 2011

Secondary Air Injection System - Water Intrusion: MIL

Section Engine Control Market USA

YEAR(S) MODEL(S) ADDITIONAL INFORMATION

2008 – 2011 Sequoia

2007 – 2011 Tundra

July 12, 2012 Rev2:

February 9, 2012 Rev1:

Any previous printed versions of this bulletin should be discarded.

© 2012 Toyota Motor Sales, USA Page 1 of 12

OP CODE DESCRIPTION MODEL ENGINE TIME OFP T1 T2

• Warranty application is limited to occurrence of the specified condition described in this

Required Tools & Equipment

REQUIRED EQUIPMENT SUPPLIER PART NUMBER QTY

© 2012 Toyota Motor Sales, USA

1GR-FE 25701-31010 25701-31011 1

1GR-FE 25701-31011 Same 1

2UZ-FE 25710-50030 25710-50031 1

© 2012 Toyota Motor Sales, USA

Parts Information (Continued)

1GR-FE 17376-50010 Same 2

© 2012 Toyota Motor Sales, USA

© 2012 Toyota Motor Sales, USA

Repair Procedure (Continued)

5. If liquid evidence is present, follow the steps below.

FOR 2UZ-FE EQUIPPED VEHICLES

• ONLY replace the Bank 2 pump.

1 Foam Seal 3 Air Inlet — Located Above RH Front Wheel

© 2012 Toyota Motor Sales, USA

Repair Procedure (Continued)

Refer to TIS, applicable model and model year Repair Manual:

Make sure the clamp orientation is as shown in Figures 2 and 3.

© 2012 Toyota Motor Sales, USA

Repair Procedure (Continued)

1 Clamp 1 Installation Orientation 7 LH

6 RH 12 Approximately 0 – 5 mm (0 – 0.2 in.)

© 2012 Toyota Motor Sales, USA

Repair Procedure (Continued)

1 Clamp Installation Orientation 5 Air Pump

© 2012 Toyota Motor Sales, USA

Repair Procedure (Continued)

© 2012 Toyota Motor Sales, USA

Repair Procedure (Continued)

© 2012 Toyota Motor Sales, USA

Repair Procedure (Continued)

• 2010 Tundra: 3UR-FE / 3UR-FBE / 1GR-FE / 1UR-FE

© 2012 Toyota Motor Sales, USA

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