P0418 Secondary Air Fault 2012 4.0L

Randomly the last couple of times I have started my truck I have been getting a P0418 Fault coming on from startup. I haven’t been driving it crazy or anything and I never let it get below 1/4 tank so the fuel pump doesn’t get damaged (don’t want to run out of gas as this thing gets crappy MPG) I uploaded all the freeze frame data. I can’t imagine the fuel pump is tired as it has no delay or miss under acceleration. Has anyone had this on a 2012 4.0L engine. Zero drivability issues, and it just passed smog. The only thing I have changed is I switched back to OEM intake from Airaid but cleared adaptions and reset everything. Also did a hard reset let all the power out of the system. I have seen it can be a sensor or something to do with the secondary air injection system, or weak pump or blockage in fuel system. I regularly use fuel system cleaners like seafoam and Royal purple Boost as I tow a lot. Any input would be awesome. I did swap relays with the heater and battery is at 12.5v as precheck as well. The temp is in the 70s and it’s during startup that it triggers every time with no load or anything on the engine. I cannot Delete the SAIS as I am in California and have to pass smog with all emissions equipment intact. I know the relay and battery have proper voltage at startup. It just started doing this out of the blue.

 

The P0418 Means there is a problem with either the Air Pump or Air Injection Control Driver or related circuits.

Does the air pump still run on a cold start?

If not I'd start with checking powers and grounds at the Air Injection Control Driver as well as the ground at the Air Pump.

 

This is a major help. I don’t have a techstream but have about 20 different OBD2 readers that can communicate. The diagnosis tree bulletin is exactly what I needed. Would much rather minimize invasive repair of replacing everything if I can single out what is actually bad.

 

I will say I recommend using a test light instead of a meter for power and ground checks because a meter doesn't load the circuit.
https://www.tacomaworld.com/threads/2nd-gen-information-diagnostics.784008/#post-28042153

I can't say I've ever seen where anyone had the Air Injection Driver go bad, it's typically the pump or a wiring issue.

 

I have heard that the 2012 had a known issue and that there was a recall for the secondary air pump but NHTSA doesn’t show it and the Toyota lookup on their website is down for my vin.

 

There was not a recall, it was a customer support program/extended warranty on the SAIS components.

It was 10 years from date of first use which would be the date the vehicle was originally sold.

The main failure on 2012s was the Air Switching Valve(s) sticking due to moisture getting stuck in them resulting in P2440, P2441, P2442, and/or P2443 codes and the truck going into limp mode, the system was revised in 2013 to cycle the pump and valves on engine shutdown to purge moisture from the system.

Another common failure is the foam filter getting degraded and sucked into the pump and valves, many people get rid of it and put a UNI 1in crankcase breather filter on the inlet port of the pump.