P2440 on Toyota: How to Diagnose & Fix
Secondary Air Injection System Switching Valve Stuck Open (Bank 1)
6 Toyota models · 8 documented issues · 2 critical · $100-$4,000 repair
P2440 on Toyota by model: symptoms, diagnosis and fix
The secondary air injection pump is prone to failure due to water intrusion. The electric motor is located in the wheel well with moisture exposure, and the rubber boot covering the motor traps water, causing the pump to short circuit. This triggers check engine lights with codes P2440, P2443, P2445, P2447, P0418, or P0419. Some vehicles may enter limp mode.
Common Symptoms
- Check engine light illumination
- Jet engine noise on cold startup
- Decreased fuel economy
- Limp mode activation
- Rough idle when cold
How to Fix
Toyota issued a service bulletin for 2007-2010 models covering replacement of the entire air injection system. Repair costs range from $2,000-$4,000 for OEM replacement. Some owners opt for aftermarket bypass kits with block-off plates.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
- Toyota 17610-0S010 genuine secondary-air pump assembly
replace the corresponding pump only when active testing and the applicable Toyota program identify it as failed Fitment/availability: Cataloged for selected 2007-2013 Tundra applications; exact engine, side/quantity, DTC branch, VIN and …
- Toyota 17610-0S030 genuine secondary-air pump assembly
replace the program-matched pump after active-test confirmation, with all required valves, inlets, gaskets and calibration handled separately Fitment/availability: Cataloged for selected 2012-2021 4.6L/5.7L applications; on this card use…
As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.
Owner tips & cautions
- TipDIY repairs can save significantly - dealer charges $2,000-$4,000 but DIY costs are typically 50-70% less
- TipConsider OEM parts for critical components like sensors and electrical parts - aftermarket can be unreliable
- TipGet a proper diagnosis before replacing parts - similar symptoms can have different causes
The 4.7L 2UZ-FE's secondary air injection system fails due to corroded air switching valves (ASVs) and seized air pumps. Moisture enters the system and corrodes internal components. Causes check engine light with P2440/P2442 codes.
Common Symptoms
- Check engine light with P2440 or P2442 codes
- Rough idle on cold start
- Ticking or buzzing noise from air pump on startup
- Failed emissions testing
How to Fix
Replace air switching valves (Toyota 25701-50040 and 25702-50011) and air injection pump (Toyota 17610-0S010) if seized. Many owners bypass the system entirely with block-off plates since it only operates during cold start for emissions. Bypass plates available from Trail Gear or fabricated from aluminum.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
- Toyota 17600-0F010 secondary air injection pump assembly
replace a debris-damaged secondary-air pump after bulletin diagnosis Fitment/availability: Exact pump listed by T-SB-0230-12 Rev1 for an eligible 2005-2007 Sequoia 2UZ-FE; replace only when bulletin inspection finds debris in the pump Fi…
- Toyota 25710-50022 air switching valve assembly
replace the corresponding failed or debris-damaged air switching valve Fitment/availability: Exact air switching valve assembly listed by T-SB-0230-12 Rev1; use only on the diagnosed valve branch and confirm VIN before ordering Fitment/a…
- Toyota 25720-50011 electric air control valve No. 1
1 valve only when its bulletin diagnostic branch confirms failure or damage Fitment/availability: Exact No. 1 valve listed by T-SB-0230-12 Rev1; not interchangeable with the No.
- Toyota 25720-50020 electric air control valve No. 2
2 valve only when its bulletin diagnostic branch confirms failure or damage Fitment/availability: Exact No. 2 valve listed by T-SB-0230-12 Rev1; not interchangeable with the No.
- Toyota 89580-34012 air injection control driver
replace the air-injection control driver on the bulletin's residual-code branch Fitment/availability: Exact driver identified by T-SB-0230-12 Rev1; use only if P0418 or P2445 remains after the applicable mechanical repair and confirmatio…
- Toyota 17171-50030 intake manifold-to-head gasket No. 1
reseal both intake-manifold-to-head joints during the applicable repair Fitment/availability: Exact gasket listed by T-SB-0230-12 Rev1; bulletin quantity is two when the applicable air-injection repair requires intake-manifold removal Fi…
- Toyota 17377-50010 air tube gasket No. 4
replace disturbed air-tube seals during the bulletin repair Fitment/availability: Exact air-tube gasket listed by T-SB-0230-12 Rev1; bulletin quantity is four for the applicable repair Fitment/availability: Ships in 1-3 business days wit…
As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.
2nd-gen Sequoias with the 5.7L 3UR-FE also suffer from secondary air injection pump failures, similar to the 1st gen but with updated part numbers. The pump seizes from internal moisture corrosion, triggering P2440-P2445 codes and check engine light.
Common Symptoms
- Check engine light with P2440-P2445 codes
- Loud buzzing or grinding on cold start
- Air pump not engaging on startup
- Failed emissions test
How to Fix
Replace secondary air injection pump (Toyota 17610-0S010 or Dorman 306-058). Replace air switching valves if corroded. Aftermarket pumps are available at lower cost. Some owners install check valves in the air line to prevent moisture backflow into the pump.
The secondary air injection system on the 200 Series Land Cruiser (3UR-FE and later engines) fails due to moisture intrusion and corrosion of the air switching valves and pump motor. The system pumps air into the exhaust manifold during cold starts to reduce emissions. When it fails, it triggers check engine lights and can prevent the vehicle from passing emissions testing.
Common Symptoms
- Check engine light on cold starts
- Rough idle for first 30-60 seconds
- Whirring noise from engine bay on startup
- Failed emissions inspection
- Multiple air injection fault codes
How to Fix
Replace the air injection pump, air switching valves, and check valves. Clean or replace corroded wiring connectors. Some owners delete the system entirely with aftermarket tune, though this prevents passing emissions in tested states. Toyota TSB-0111-10 addresses the updated valve design.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
- Toyota 17610-0S010 genuine secondary-air pump assembly
early pump branch, replacing only the unit proven failed by command and electrical/flow testing Fitment/availability: VIN- and production-date-confirmed 2008 through early-2013/2014 Land Cruiser 3UR-FE branch; catalog requires quantity t…
- Toyota 17610-0S030 genuine secondary-air pump assembly
later pump branch after component-specific diagnosis Fitment/availability: VIN- and production-date-confirmed late-2013 through 2021 Land Cruiser 3UR-FE branch; catalog requires quantity two Fitment/availability: Live direct product page…
- Toyota 25701-38064 genuine electric air-control valve assembly
replace only after active testing proves the electric valve is stuck, leaking or electrically failed Fitment/availability: VIN-confirmed 2008-2021 Land Cruiser 3UR-FE catalog branch; exact production supersession and associated gaskets m…
As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.
Owner tips & cautions
- TipRequest the updated air switching valve design per TSB-0111-10 when replacing - the revised valves have better moisture sealing.
- WarningDeleting the air injection system will cause a permanent CEL and emissions test failure. Only viable in non-emissions states.
The secondary air injection (AI) system on the 100-series Land Cruiser (1998-2007) with the 2UZ-FE 4.7L V8 is a notorious failure point, identical to the issue on the Sequoia and Tundra of the same era. The electric AI pump, air switching valves (ASV), and exhaust manifold check valves all fail. The aluminum check valves in the exhaust manifolds corrode and seize, the ASV sticks from carbon buildup, and the pump motor eventually burns out. This system is responsible for the most common check engine light on 100-series Land Cruisers.
Common Symptoms
- Check engine light with air injection codes
- Loud whirring from AI pump on cold start
- AI pump not running on cold start (silence where there should be noise)
- Multiple emissions-related fault codes
- Failed emissions inspection
How to Fix
The complete repair involves replacing the AI pump ($300-$500), both ASV valves ($200-$400 each), and both exhaust manifold check valves ($100-$200 each). Total dealer cost: $1,500-$3,000. Many Land Cruiser owners in non-emissions states delete the entire AI system and install an ECU tune to suppress the codes ($300-$500 for the tune). In emissions states, the full repair is required. A common partial fix is to replace just the check valves and ASV, leaving the pump in place — the pump usually fails last.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
- Toyota 17600-0F010 genuine secondary-air pump assembly
bulletin-specified pump replacement after the covered DTC diagnostic path confirms the condition Fitment/availability: VIN-confirmed 2005-2007 Land Cruiser 2UZ-FE; T-SB-0230-12 repair authority is limited to applicable 2006-2007 vehicles…
- Toyota 25710-50022 genuine secondary-air control/check valve
replace only when inspection under T-SB-0230-12 shows debris damage to this valve Fitment/availability: VIN-confirmed 2005-2007 Land Cruiser 2UZ-FE; current valve replaces 25710-50020 and 25710-50021 Fitment/availability: Live direct pro…
As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.
Owner tips & cautions
- TipJoin IH8MUD.com — the definitive Land Cruiser forum. The AI system delete with ECU tune is thoroughly documented there with step-by-step instructions and recommended tuners.
Sources for this issue (1)
Tacomas with the 1GR-FE 4.0L V6 are known for failures of the secondary air injection system, including the air pump and switching valves. Moisture intrusion and valve sticking can trigger check-engine lights and force the truck into reduced-power or limp mode. Owners frequently report sudden loss of acceleration along with expensive dealer repair estimates because the intake manifold often must be removed to access components.
Common Symptoms
- check engine light
- TRAC/VSC lights on
- reduced power or limp mode
- poor acceleration
- cold-start abnormal pump noise
How to Fix
Diagnose with a scan tool and active tests to determine whether the pump, bank valves, or control circuits have failed. Repair usually involves replacing the failed air pump and/or switching valves, checking related vacuum/electrical connections, and clearing codes after verification. Some owners install bypass modules, but emissions-compliant repair with quality parts is the proper fix.
What you need to diagnose it
The repair instructions explicitly call for reading stored codes. Use a scanner that can read the named code families before choosing a repair.The recommended scanner supports these code families; confirm your exact year, model and module coverage before buying.
ANCEL AD310 Classic OBD-II Scanner
Read & clear engine (P) codes
$20–$40View
As an Amazon Associate, we earn from qualifying purchases. Prices are approximate and may vary.
Reading and clearing the code is DIY work. Module replacement or reprogramming is not — most modules are VIN-programmed, so a new one does nothing until a shop codes it to your car. Check for an open recall or service bulletin before buying anything.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
- Toyota 17610-0W020 genuine secondary-air pump assembly
replace the pump only when Toyota's active-test and DTC/inspection branch requires pump replacement Fitment/availability: Toyota's T-SB-0333-17 repair part for the VIN-specific 2012 Tacoma 4.0L 1GR-FE Mexico-production branch; confirm VI…
- Toyota 25710-31022 genuine secondary-air switching-valve assembly
replace a moisture-damaged or stuck switching-valve assembly as part of the Toyota-prescribed repair set Fitment/availability: Superseding switching-valve assembly specified by T-SB-0333-17 for the affected 2012 Tacoma 1GR-FE Mexico-prod…
- Toyota 17613-0P010 genuine air-pump protective cover
reduce repeat filter damage after the confirmed secondary-air-system repair Fitment/availability: Toyota T-SB-0333-17 and CSP ZHA cover for the affected 2012 Tacoma 1GR-FE repair; confirm VIN and use with the complete prescribed pump/val…
As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.
Owner tips & cautions
- TipIf the truck enters limp mode with P2440-series codes, diagnose the air injection system before replacing unrelated sensors.
- TipAddress water intrusion and inspect hoses/connectors during repair, since moisture is a common contributor to repeat failures.
Sources for this issue (2)
P2440 code reference
General diagnostic-code context. The code alone does not confirm a cause for your vehicle; use the applicable issue card and its sources.
Frequently asked questions
What does P2440 mean on a Toyota?
P2440 stands for "Secondary Air Injection System Switching Valve Stuck Open (Bank 1)." P2440 indicates the secondary air injection (SAI) system's switching/diverter valve on engine bank 1 is stuck open. The secondary air system briefly pumps fresh air into the exhaust at cold start so the catalytic converter heats up and lights off faster, cutting cold-start emissions. The computer commands this valve closed once warm-up is done; if it senses the valve hasn't closed (air is still flowing when it shouldn't be), it sets this code. A stuck-open valve can let exhaust pressure or moisture back into the air pump and skews the oxygen sensor readings during warm-up. On Toyota it is documented across 6 models: Tundra, Sequoia, Land Cruiser, Tacoma, FJ Cruiser, 4Runner.
What are the most common causes of P2440?
The most common causes of P2440 are: Air switching/diverter valve stuck open or seized, Carbon, rust, or debris fouling the valve, Faulty valve vacuum control solenoid or leaking vacuum line, Corroded or moisture-damaged secondary air pump, Wiring or connector faults at the valve solenoid, Clogged or failed combination/check valve, Vacuum leak preventing the valve from closing. The specific cause varies by vehicle.
How much does it cost to fix P2440 on a Toyota?
Published repair estimates on Toyota range from $100 to $4,000 depending on the model and root cause. If an issue mentions a recall or campaign, check your VIN with the manufacturer or NHTSA and confirm eligibility and coverage with a dealer.
Looking for P2440 on a different make?
View P2440 across all makes →Content compiled with AI assistance using NHTSA complaints, TSBs, and owner reports. May contain errors. Always verify with your vehicle's service manual.