What Parts Are Needed To Repair A Secondary Air Injection Pump In My Toyota Tundra

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jtx0741 [OP] New Member

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2013 Tundra 4.6 V8
Turned on the truck and the 4lo, check engine, and trac off lights were all on. After looking online I saw it's a pretty common problem on Toyota with the secondary air injection pump seizing. I checked it with the code reader at a local shop and the guy confirmed it, code P2240 "Air Injection Switching Valve Stuck Open Bank 1." He told me he used to work for Toyota and knew there was the extended repair on this issue but couldn't recall the specifics. I went into Toyota and unfortunately they will not cover it for my year truck.
I cant seem to find anything on a 2013 tundra Air Injection Pump, but was hoping it could be fixed with something as simple as a bypass kit, but I wouldn't even know where to begin.

Toyota told me the fix would cost about 2k, but the shop quoted me 1k.

Anyone know about pricing fixing or the location on a 2013 model?
osidepunker OsidePunker

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Just google tundra AIP bypass. Theres a good kit out there you can use
jtx0741 [OP] New Member

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I tried googling the bypass, but I keep getting bypass kits for 2007-2012. I have not been able to see anything for 2013 and up.
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osidepunker OsidePunker

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Toyota Extends Air Injection Pump Failure Coverage to Certain 2012-13 Tundra
https://tundraheadquarters.com/extends-air-injection-pump-coverage/
jtx0741 [OP] New Member

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I found this one from hewitt tech and it seems pretty simple to install even for a not so mechanically inclined person such as myself. Just one more question, does this fix the issue or just clear the codes? the guy from Toyota had told me running the tundra in it's current state could mess up the cat, so is this going to affect it down the road? or was he just trying to make 2k?
jtx0741 [OP] New Member

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I took it in to the dealership and they weren't able to find anything for my specific truck besides a door handle fix. I even called the dealership I bought it at and they said the same thing. The guy told me they could run a diagnostic test in the back and when they actually plug it in they "sometimes find a warranty they hadn't previously found just by the vin" but if they dont, it's a $100 charge to plug it in.
Buildn 2017 Tundra Dbl Cab TRD 4x4

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I had the pumps replaced twice on my 2008.
Then it was covered both times by the 100,000 mile warranty.

The 2 grand cost is mainly for labor because of where the pumps are located and how many things have to be removed in order to reach them.

I know on the net there are kits that bypass but I'm not sure if after the codes are reset or cleared if they will return causing your trick to fall back into limp mode or if the after market bypass gives you emissions problems causing you to fail.

I know that the replacement pumps are a revised design.

Maybe contact Toyota directly and see if they can help with the cost of the pumps. I have had great luck with Toyota Corp. on other costly repairs in the past.
OP, I bought the kit from Hewitt for my 08 last fall. Email their customer support or call them. They were very knowledgeable about their products as well as the issues with the Toyotas. When I spoke with them, they still perform testing on their own vehicles that have these kits as well as test and continue developing new products.
I had my AIP pumps replaced under warranty once and when they failed again, my truck was out of warranty by 3 months. I called corporate Toyota like what seems like a long list of others, and had zero luck getting them to budge on any type of price help. The first set of pumps I had replaced had been on there less than 3 years and failed again.

The Hewitt Kit is EXTREMELY easy to install, I was a little worried myself. If I remember correctly, this bypass kit hooks up and essentially keeps the systems turned off. You aren't necessarily fixing the issue, but with bypassing the system, you aren't needing it any longer. The kit also comes with exhaust block of ports that were easy to install as well. When I picked mine up (they are local to me), they still have these kits run on their personal vehicles, and were very helpful. I installed mine back in October and haven't had any issues since.
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osidepunker OsidePunker

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I didn't see one on their website, just a AIP pump filter relocation kit
osidepunker OsidePunker

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How many miles on your truck? Its supposed to be covered up to 100k
Also, apparently the Hewitt Kit doesn't work on 2013 and newer if you've had the ECU update. They are developing a new kit that should cover all the years and it should be available this year. I just emailed them about beta testing so we'll see
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yes you right just a relocation kit.
jtx0741 [OP] New Member

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it's got 140k.
The mechanic just said that its gonna need the switch under the manifold to be replaced so he said it would be another $499 and its just gonna fix one side of the truck. I'm hoping the Hewitt Tech bypass kit passes smog. I wasnt able to get a hold of them over the phone.
jtx0741 [OP] New Member

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I'm not sure if its had an ECU update. I've never been told they updated it or asked for it to be updated. How would I know if it's an updated ECU?
osidepunker OsidePunker

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There's a sticker under the hood
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First post - stoked to own a Tundra! But after 3 months of ownership on a 2013 4.6L 4x4 Tundra, had the secondary AIP fail. The official codes it threw were P1604 (startability malfunction) P1605 (rough idling), P2440 (secondary air injection system switching valve stuck open Bank 1) according to Toyota dealership. Cost was just under $3k to fix. I believe they planned to replace pump, valves and switches.. So, I fought with my dealer that I bought the truck from to pay for repairs at Toyota, but they were not willing. Then, after talking with Toyota dealership, they advised me that they could ask Toyota Corporate to help with repairs.. it only took 2 days to get word that corporate was willing to cover cost of all parts needed, about $2500 worth, and I would pay the $500-600 for labor. All that being said, I was able to talk to my original dealer to help with cost of labor, and I'm having the truck fixed for about $350. However, I also spent a long time on the phone with Hewitt about their bypass kit. They let me know that the kit would eliminate all codes and current issues with my Tundra and would not cause future emissions issues.. I was ready to just get my truck back, unfixed from dealer, and install the bypass kit, but when they agreed to fix all for $350 out of pocket, I agreed.. I do plan on installing the Hewitt kit when I get some extra cash, because Hewitt said even when customers had their AIP replaced by Toyota, they had failure issues about 12-18 months after replacement and they wished they had bought the bypass kit.
So, I hope this is helpful to someone with this issue who isn't covered under warranty— get the Toyota dealership to ask for help from Toyota corporate, and in either case fixed or unfixed, just install the bypass kit. I also advise calling Hewitt with your problem codes from the truck and talking options with them, they are very helpful!
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good to know.thanks. do you live in a state where it's pretty humid ? that's usually when the AIP fails.
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Dallas Tx - very humid recently! That's good to know!

equin and TheBeast like this.
I agree, Hewitt was very informative on their products. I had my AIP kit replaced under warranty and mine failed again about 2 years later. I went ahead with the bypass and have been running it about 6 months and seems to be fine.
My friend had this happen to him on his 2010. He got a bypass kit and fixed it for about $300
MXracer21 New Member

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I have a 2007 Tundra 4.7L. Back in 2013 I had a failure with the AIP system and was fixed under warranty. No issues up until September/October of last year when one of my switching valves was stuck open. So I paid $600ish for parts and labor. Now I had another CEL with a P2442 code with the other switching valve stuck open and my truck going into limp mode. So I wasn't going to pay $600+ in parts and labor again, and potentially deal with issues in the future with the AIP system, so I went with the Hewitt Tech kit for my truck. I got it in today and it took me about 20-30 mins to install from start to finish. I disconnected the battery to clear the code, and it started right up, with no codes, no more limp mode, and no loud vacuum-like noise at startup.
I highly recommend the kit, if you are having issues with the AIP system. I didn't research any other bypass kits, but the Hewitt tech was the one that I heard about in another thread somewhere.
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Ah this is what I wanted to know. This explains why I only see bypasses for up to 2012. I have a simple one from another member on my 07 that works great but would like to disable on a 3rd gen, not just relocate the intakes for it. Any updates?
osidepunker OsidePunker

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They have a new Gen-II SAIS Bypass kit that works for all years. Looks like if you get a separate presser sensor deal you can completely bypass and remove the entire system. Its not cheap, but its something I will probably do in the near future.
If you just have the valve code... buy just the valve and replace. It's like 200 bucks I think. Not hard to swap. I did it in the parking lot at work at lunch.
osidepunker OsidePunker

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I dont have any codes, but I want to bypass the system to remove a possible point of failure
Gotcha. Yeah it's a pita system.
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Glad it worked out for you with Toyota corporate....my experience has been a total loss.
My 2012 Tundra 4.6 had the dreaded code 2440 (bank 1 stuck open) six months ago right at 72k miles. Dealer refused to help with warranty, wanted just short of $3k for repair, so it escalated to two weeks of back and forth with corporate and zero help there. Corporate even stated they know it is still a problem, but won't extend the warranty repair to post 2011 models. Even with my extended warranty. So, I had an independent shop replace the bank 1 valve for $500.
So, six months later/yesterday my Tundra threw the code again and we are back in limp mode....ugggggh.

Maybe the Hewitt bypass is the way to go. I wrote Hewitt and my mechanic has heard of the bypass, but has no experience with it....I'm getting desperate. I am skeptical and reluctant to re-engineer my truck, but Toyota is zero help unless I pay them $3k just to see if they can fix it.....Any suggestions, anyone?
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Secondary Air Injection System Bypass Kits

Hey guys, just ran across this forum and a couple of threads and figured I would stop by to say hello. If anyone has any questions about our bypass kits just let us know.
I did see someone mention our new GenII kits a few posts back. It is by far the most advanced and complete solution for a faulty secondary air system on the Toyota and Lexus vehicles.
It currently covers all of the Toyota Lexus vehicles from 2005-2019(current model year). The only gap in its current coverage is some of the 4.7L vehicles but we will get those covered in the next few months or so with a different version. The GenII installation is even simpler than our current V36 and V54 units with no need for the starter relay sense wire that connects to the starter relay and we don't have to mess with things at startup.
It is a complete standalone solution. If anyone has any questions please give us a call Toll Free 844-307-7671 or email Support@hewitt-tech.com
osidepunker OsidePunker

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Thank you for participating in this thread.
So in other words, if I buy the genII kit, I can completely remove the entire AIP system???