P2440 error code

I have a 2007 Tundra 4.7L TRD, 130k miles. The other night my instrument panel lit up like a Christmas tree - 4lo blinking, VSC lit up, traction control lit up, check engine light lit up as well - and remains that way, even after disconnecting the + battery terminal, which works and resets it all until I drive off. Truck seems to be in limp mode; loss of power and won’t push past 50mph or so, and there is an audible difference in the engine at idle and while accelerating. (Suddenly sounds like I have more than a 4.7 under the hood)

Got P2440 error code “secondary air injection system switching valve stuck open (bank 1)” and truck is beyond extended warranty. This is getting into an area that may be over my head in but I have considered doing it myself, have done a few relatively minor things myself on the truck and have access to hobby bays w lifts and all tools on base here, but have also considered trying the SAIS bypass. I’m guessing what I’m hearing in the engine is the valve stuck open like the code indicates. Also considered just making an appointment but sounds like it could get pricey.

So, being relatively new to tinkering, and needing this truck to work properly, I’m trying to figure out if I should:

-Attempt to replace the Secondary Air Injection Pump (not sure which of the two is which) myself. YouTube obviously makes it look easy..
-Try the SAIS bypass (will this close the valve if it’s truly stuck open?)
-leave it to the pro’s

Any input or guidance of any kind is greatly appreciated. Cheers!

 

With the bypass, my understanding is that the valves will be stuck in whatever position they are currently in, but the included block off plates make it a moot point. This is what I will be doing when I do my longtube header install as preventative maintenance.

 

I would do the bypass and never have the issue again.

 

So the block off plates will essentially negate the air pump and its sensors all together, open or closed valves don’t matter either way? Just making sure I’m tracking correctly.

 

That is my understanding of how it works. Here is an install video that may help. My kit just showed up 2 days ago, so I don't have any direct experience with the install (yet).

https://www.youtube.com/watch?v=3xkEBcFJcG8

 

Thanks Ben, and Phil. That's the SAIS bypass I was looking at picking up, think I'll order one tonight. This was also in the FAQ section of their page:

"[...]the block off plates are an integral part of the solution. In cases where the actual Air Switching Valves are physically stuck open or leaking the block-off plates are 100% required."

...so I guess that answers that.

 

Hey guy I know I am late to the Party but wanted to add some additional information about the importance of the Block off Plates with Hewitt Technologies Bypass Kit. We strongly encourage and recommend the installation of block off plates. We say this because if you have a valve stuck open code or if your valve would become open the block off plates would protect from any Exhaust from leaking in. If exhaust get in the valve it could damage the pressure sensor which would throw your truck into limp mode and a kit addon would be required to clear the code. Lastly, it could create a small exhaust leak if the valve is stuck open which could be hard to diagnose because the bypass kit is preventing error codes from being triggered.

What Does the Secondary Air Injection System Do?
https://www.tundras.com/threads/what-does-the-secondary-air-injection-system-do.113683/

What Do My Secondary Air Injection Error Codes Mean?
https://www.tundras.com/threads/what-do-my-secondary-air-injection-error-codes-mean.113686/

How to Fix Secondary Air Injection System?
https://www.tundras.com/threads/how-do-you-fix-the-secondary-air-injection-system.113688/

Do not hesitate to contact us with any questions,

 

Just found this thread- my 08 Tundra Crew max just had this issue (driving, lights come on, limp mode)
Toyota said it was P2440.
My questions with the by-pass are
1. Will the truck still pass emissions?
2. Will having the block off plates, will it shorten the life of the Catholic converters?
3. If a by-pass is install, I assume it can be reversed (back to a pump/valve system)?
Any help on this is appreciated

 

1. Yes
2. No
3. Yes

The SAIP have only 1 use they inject air into the exhaust manifold at a cold start up for about 30 seconds to reduce emissions.

 

Thank you- I’ve been debating on the by-pass or replace valve and pumps (so much cheaper and faster than a full replacement- just sounded to good to be true)
Thanks again

 

good to know it doesn't mess with emissions testing. i have the same 2007 4.7 with 275K and just got this shit last week. luckily my truck is a weekend warrior so i have time to research and learn how to install the thing. i just spent $1700 on other parts to get this thing driving nicely, not looking forward to spending another ~$500.

 

So I did the Hewitt by-pass and I still draw codes- most are bank 2 sensor 1 but
the sensor has been replaced with OEM one- I clear codes and get a MAF code but that’s brand new too- Hewitt sent over a check list of things to do- did them all- still get codes every now and then BUT only when I exceed 65mph.. I’m going to replace the stuck valves and remove the by-pass…mine is a 5.7L which is way more difficult than the 4.7 (where the valve is located)
I often see people complain about Hewitt gen 1 vs gen 2… I have a gen 1 (maybe that’s the issue)
Good luck

 

GREAT TO HEAR

 

just bought the gen 2. wish me luck.

 

installed the gen II hewitt bypass kit on my 2007 4.7 today. it was pretty easy, although i did have to figure a few things out for myself. the instructions weren't quite clear for a couple things, like the bolts for the block off plates. there's one picture for those and it does not describe the bolts well. i was about to unscrew the wrongs ones when i looked at the block off plates and took a second look. all in all a pretty easy job with minimal tool requirements. i did have to use a 22" long ratchet extension to get to the bolts from under the truck. passenger side had too much shit in the way for my big dumbs hands and ratchet from the top. anyway, got it done! codes are gone, truck runs great. truck runs! installed a new clock spring today, too. and got new windshield wipers. and didn't wreck anything on my truck or make something worse. feeling accomplished!