P2440 Secondary Air Injection System Valve Stuck Open Bank #1

If you are reading this article, you already know the Secondary Air Injection System on Toyota and Lexus vehicles is failure prone. The Secondary Air Pumps and Air Switching Valves are notorious for Mechanical and Electrical fault codes. Unfortunately, the reality is not “If” these components will fail but “When” they will fail. The following is aimed to help you better understand the Mechanical error code P2440 and what can be done to address it.

Diagnostic Trouble Code (DTC):
P2440 – Secondary Air Injection System Switching Valve Stuck Open Bank #1

What Does P2440 Mean?
Typically, P2440 is tripped because the Bank #1 Pressure Sensor detects pulsation of exhaust gas despite ECM commanding the Air Switching Valve to close. Meaning the Switching Valve is Stuck Open. However, there are other circumstances and conditions that can cause P2440 which will be further explained below.

How To Fix P2440
The most expensive option is having Toyota or Lexus replace the Bank #1 Air Switching Valve with Factory/OEM Components. On average, most Dealerships will quote between $2,000 – $3,000 for parts and labor. Depending on your engine size, you may need to replace both Air Switching Valves and could involve removal of the intake. However, replacing the Air Switching Valve only partially addresses the Secondary Air Injection System and even worse may only be temporary. This option does not prevent the other Air Pumps or Valves from failing or even guarantee the new Air Switching Valve from failing again in the future.

The most comprehensive and cost-effective solution is the Hewitt Tech Bypass Kit. Our Secondary Air Injection System Bypass Kits and Kit Addons are engineered to address multiple types of fault codes across entire Secondary Air System. Additionally, the “Plug and Play” design is compatible with the factory harness which mean you will not have to remove the intake. That said, if you want to get out of Limp Mode, turn off your Check Engine Light, avoid future failures and save thousands of dollars; a Hewitt Tech Secondary Air Injection Bypass kit is what you need.

There is one last option we would like to warn you against. DO NOT, I repeat, DOT NOT replace Secondary Air Injection components with cheap aftermarket parts. An initially attractive choice, aftermarket parts will end up costing you more in time and money in the long run. These components are more failure prone then the factory parts. It is not uncommon for them to fail a few weeks or months after installation. This is largely due to the poor-quality materials used to make them and it is not unusual to have aftermarket parts warrantied 2, 3 or even 4 times because codes return.

What Causes P2440?
The primary reason for P2440 is Mechanical failure of the Air Switching Valve. Many factors contribute to this failure including moisture entering the system, debris from Air Pump, carbon build up or general wear and tear. Any one of these can lead to the Valve being “Stuck Open”. There is also the potential for intermittent valve codes due to extremely cold weather conditions. This can affect operation of the Air Switching Valve and will usually resolve itself once the vehicle or the weather warm up.

However, in addition to Mechanical failure, there are several other reasons P2440 can be tripped. This includes damage to the; Pressure Sensor, Air Injection Control Driver, ECM or factory wiring harness and connectors. If the P2440 code can no longer be cleared, then damage to one of these components is most likely the cause. This can make troubleshooting difficult and frustrating because simply addressing the Air Switching Valve will not resolve the issue even though that is what the error code is indicating. Please note to address a P2440 caused damaged pressures sensors, will need the Pressure Sensor Kit Addons in addition to the Bypass Kit.

Lastly, if aftermarket parts were installed on the vehicle this could also be the root cause of P2440 error code. This can be the case if the valve has failed mechanically or if Pressure Sensor located inside the valve is no longer reading accurately. Both scenarios are common because again these parts are garbage. That said, if aftermarket parts are installed on the vehicle there is a very good chance P2440 could still be present after installation of our Bypass Kit. A Pressure Sensor Kit Addons would then be needed to address.

WARNING:

Repeatedly clearing P2440 and continuing to drive the vehicle with a” Valve Stuck Open” code can cause damage to the Pressure Sensor. Further neglecting this code can even result in damage to the ECM.

Relates Error Codes
Mechanical:
P2441 – Secondary Air Injection System Switching Valve Stuck Closed Bank #1

P2442 – Secondary Air Injection System Switching Valve Stuck Open Bank #2

P2443 – Secondary Air Injection System Switching Valve Stuck Closed Bank #2

Electrical:
P0412 – Secondary Air Injection System Switching Valve “A” Circuit

P0415 – Secondary Air Injection System Switching Valve “B” Circuit


Additional Secondary Air Injection System Resources
To learn more about the purpose, components and other fault codes of the Secondary Air Injection System; click on the following Must Read Hewitt Tech Blogs links.

• What is the Secondary Air Injection System?
• What Do My SAIS Error Codes Mean?

Disclaimer
Hewitt Technology’s SAIS Bypass Kits and products are sold for off-road, competition or other emissions exempt vehicles only. It is illegal to remove, dismantle or otherwise cause to be inoperative any pollution control device required by federal, state, or local emissions law. No other applications are intended or implied.

 

Hey Hewitt

My 2015 just came up with P2443 secondary air injection switching valve stuck closed bank 2..
And Toyota was rather quick to give me a $2600 quote to fix the switching valve $1427+$167 labor, gaskets $11 and Air Pump $1003.

I have been told that there was a recall for this but if course it had already expired..
I'm looking into an aftermarket extended warranty my truck came with... They better cover it..

If not, I'm sure there's an aftermarket fix for this bullshit..

Regards,
Matt

 

@TacoNorth2010 Your assumption is correct, do not install aftermarket (Dorman) components. These parts are cheap for a reason and will only cause you more headache and frustrations. Even if you repair with factory/OEM components that does not prevent it from failing again in the future. I hope the Expended Warranty covers it for you but if not give us a call, the Gen 2 Bypass Kit is what you be looking for.

Secondary Air Bypass Kit: Gen 2 (Plug & Play) | Hewitt Technologies (hewitt-tech.com)

DM if you have any questions

 

I just installed the Gen2 kit today and it was easy enough expect for one glitch. The Air Valves on my 4.0L engine were both on the same side and the air conditioning lines were in the way of the valve nearest the firewall. I wanted to install the blank off plates and this is were I had a problem. It took me an hour, with lots of breaks, to get the plate in but I did it. I took the truck for a twenty minute ride after the installation and all is good with the world. The truck started and ran well and the the engine check light did NOT come on. I have 102,000 miles on my truck and I felt I was due for some kind of failure with the Air Injection System so I decided to be proactive. I would recommend this kit to a friend. Cheers, AL

 

@AL W We really appreciate you sharing your experience and commend you for being proactive in with the SAIS. I agree the block of plates installation can be frustrating at times but well worth the time. If there is anything else we can be of assistance please let us know.

 

My 2012 tacoma went into limp mode today while accelerating to 50+mph on the freeway. with check engine and trac light on. I got codes p2440 and p2442. I reset the OBD, and the engine + Trac lights went off. I drove home 30min with no issue, going as fast as 50-55mph.

I disconnected the fan hose that leads to the injection valve, blew into it, and found that the valve is not stuck open.

I'm no mechanic, but from what I've read on these threads and watched on YouTube, that leans more towards the secondary air injection fan, rather than valve? Could the fan or valve have temporarily stopped working properly?

I'm not planning on fixing this myself. Just trying to get led into the right direction and save myself some $$.

 

@MackTaco86 The P2440 and P2442 are both Valve codes. You can clean them and attempt to get them from sticking but once you start tripping these error code the components are on their way to failure.
We inform any customer who calls in with a "Valve Stuck Open" code (P2440/P2442/P1441/P1444) to limit the amount of driving if possible. Whenever there is a valve stuck open there is potential for exhaust to leak in to the Air Switching Valve and damage the pressure sensor. If you can currently clear your codes and get substantial drive time before they trip again, that is a good sign you have not done any major damage to your pressure sensors yet. However, the quicker it come back the more likely the pressure sensor has been damaged. That said, if you cannot clear it or comes back pretty quickly then you would most likely need to get the Pressure Sensor addon.

As mentioned above there are a few options to address these error codes.

How To Fix P2440
The most expensive option is having Toyota or Lexus replace the Bank #1 Air Switching Valve with Factory/OEM Components. On average, most Dealerships will quote between $2,000 – $3,000 for parts and labor. Depending on your engine size, you may need to replace both Air Switching Valves and could involve removal of the intake. However, replacing the Air Switching Valve only partially addresses the Secondary Air Injection System and even worse may only be temporary. This option does not prevent the other Air Pumps or Valves from failing or even guarantee the new Air Switching Valve from failing again in the future.

The most comprehensive and cost-effective solution is the Hewitt Tech Bypass Kit. Our Secondary Air Injection System Bypass Kits and Kit Addons are engineered to address multiple types of fault codes across entire Secondary Air System. Additionally, the “Plug and Play” design is compatible with the factory harness which mean you will not have to remove the intake. That said, if you want to get out of Limp Mode, turn off your Check Engine Light, avoid future failures and save thousands of dollars; a Hewitt Tech Secondary Air Injection Bypass kit is what you need.

There is one last option we would like to warn you against. DO NOT, I repeat, DOT NOT replace Secondary Air Injection components with cheap aftermarket parts. An initially attractive choice, aftermarket parts will end up costing you more in time and money in the long run. These components are more failure prone then the factory parts. It is not uncommon for them to fail a few weeks or months after installation. This is largely due to the poor-quality materials used to make them and it is not unusual to have aftermarket parts warrantied 2, 3 or even 4 times because codes return.

Feel free to give us a call if you have any questions (844) 307-7671

 

I really appreciate your response and help! I will call the number provided to get some additional details. From what I've researched, your products have fantastic reviews and results.

Thanks!

 

@MackTaco86 I am glad you research pointed you in our direction and looking forward to helping you.

Kindly,