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Fault code p2440 toyota Tundra 2012

Discussion in '2nd Gen Tundras (2007-2013)' started by Gradysail, May 30, 2017.

  1. May 30, 2017 at 7:13 PM
    #1
    Gradysail

    Gradysail [OP] New Member

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    A few days ago my 2012 Tundra CrewMax TRD SR5 flashed a check eng. light after cranking the second time that day and went into "limp mode". I followed up with the dealer the next day. Over the phone they told me this problem was covered under a special extended 10yr/150k warranty. I took it in They verified the code my ODB-II found which was for a Air Injection System failure and called me later with their bad news: according to them the warranty is only up to 2011 model was covered and after that ONLY the 5.7L engines are covered! I have the 4.6L. Of course I was not happy, especially with the $2200 price tag to repair it. I did not allow them to "fix" it b/c my intention was to take it up with Toyota Customer Care the next day even though they still charged me the hundred dollar diagnostic fee.

    When I got home, I thought "what the heck" might as well use my bluetooth ODB-II device and clear the fault. I did and the check light when off but the traction ctrl light did not. I killed the ignition and restarted and this time no warning lights at all. The truck has been running fine for 2 days now and seems to be fine. The ODB showed all systems normal. Apparently there was either a false positive or it was a temporary glitch with one of the valves. Either way, my advice is if you have this error, make sure the dealer checks the fuses to that system, ask them to reset the fault to see if the component really is "bad" before forking out the mucho dinero. Also, Toyota should cover ALL their cars/trucks with this component system that seems to have issues/glitches and not leave one engine model hanging on an island by itself. The TSB fix on the 5.7s is to "flash" or reset the computer fault but they do not address the 4.6s. I did that on mine and it seems to have cured the problem. The moral of the story is invest in your own ODB device and hold the dealer accountable to their diagnosis...the internet is a wonderful thing.
     
    JTP likes this.
  2. May 30, 2017 at 8:47 PM
    #2
    Wynnded

    Wynnded What MPG...

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    He'll be back.
     
  3. Jun 2, 2017 at 7:52 AM
    #3
    JTP

    JTP The Big Black Moose

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    Thanks for the info and heads up. Seems to be a lot of this type of "glitch" and lights stuff going on. Especially with the older 1st and early 2nd gen trucks. Was on a road trip these past few days with mine and talked to two different older Tundra owners who both said the same thing. That they were getting a barrage of lights and false indication issues.

    What ODB device do you have?
     
  4. Jun 2, 2017 at 6:59 PM
    #4
    Gradysail

    Gradysail [OP] New Member

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    https://play.google.com/store/apps/details?id=org.prowl.torquefree&hl=en

    It's a relatively inexpensive bluetooth ODB-II that uses this app on your smart phone. I just keep it plugged in and I've had to reset the fault code twice since this started. That get's the truck out of limp mode and it runs normally. This system is just an emissions system and runs only for about the first 1-3 min after start up. I apparently have a clogged or corroded valve b/c it only seems to do it when the humidity is high and the engine has cooled over night. Once it runs and warms up, it's fine. However, today a new development, after some back and forth, Toyota has agreed to cover 80% of the cost to repair...basically I pay some labor and taxes. That makes me feel much better about future purchases seeing as I've been exclusive Toyo since 1993 and have purchased 1 Fourunner, 4 Tacomas, 1 Tundra, 2 Solaras, 1 Lexus, and 1 Highlander over those years. I felt like they needed to step up and they did. Best of luck to the rest of you out there on this issue.
     
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  5. Sep 16, 2017 at 7:59 PM
    #5
    crappie4me

    crappie4me New Member

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    New guy here. Got the p2440. Just had the entire secondary system replaced. NOW after every 4th start up I get a P2447. (2nd fan closed) and it goes into limp mode. Currently back in shop and they cannot find anything wrong. All fans, valves, o2 sensors, pressure switches, every component that operates the system is working fine as it should. Any suggestions? ( 2010 tundra )
     
  6. Mar 10, 2018 at 4:58 PM
    #6
    FrozenTundra

    FrozenTundra New Member

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    I just got the p2440 code on my 08 Tundra. Just missed the 10 year window by 25 days so dealer wouldnt fix. I called Toyota and asked if they would authorize the dealer to fix it but they said sorry nothing we can do. I am aware of the limp mode but has any one noticed their truck shifting sort of studdering?
     
  7. Mar 10, 2018 at 5:05 PM
    #7
    ColoradoTJ

    ColoradoTJ Certified tow LEO Staff Member

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    Calibrated Power 5 Tune pack, Allison 1000 tune, PPE deep trans pan, Cold/Hot CAC pipes, Banks CAI, PCV reroute, resonator delete, S&B 62 gal fuel tank, B&W GN hitch
    Have you done any updates through Toyota concerning the AIP system?

    If not, you might get lucky with the bypass kits. However, for this to work, I believe you need to have no codes with the AIP.
     
  8. Mar 11, 2018 at 9:10 PM
    #8
    Troynjade

    Troynjade Beast mode 5.7

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    Ive had 2 of the AIP's replaced in my 2008, the first one was covered through toyota and the 2nd costed me 2600.00, Im already worried about the 3rd time..
     
  9. Mar 12, 2018 at 3:58 AM
    #9
    Wynnded

    Wynnded What MPG...

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    You could get the by-pass, it's literally plug and play.
     
  10. Mar 12, 2018 at 5:27 AM
    #10
    FrozenTundra

    FrozenTundra New Member

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    I will most likely do the bypass but was curious if any one has noticed theier shifting sort of stutter as a result of this code / issue.
     
  11. May 17, 2020 at 6:17 PM
    #11
    Pmoore849

    Pmoore849 New Member

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    I have this code coming up now. Will Toyota honor the warranty if I wasn’t the original owner? I’d that a warranty on the vehicle itself or only for the original owner?
     
  12. Aug 16, 2022 at 5:30 PM
    #12
    Roland

    Roland New Member

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    Hi,
    First time posting here. 2012 4.6L Tundra. Had bank 2 AIP and valve replaced 3 yrs ago. Bank 1 codes started last year. Didn't want to give Toyota any more money for something they should cover for free. Bought a code reader and have been resetting the codes since. Last month two codes switched to permanent. Code reader won't reset codes. Bought the Hewitt bypass kit with the pso options. Easy install but codes are still on ECM and truck still in limp mode. Has anybody had or heard of this condition?
    Please advise.
    Thanks
    Chris
     
  13. Aug 16, 2022 at 5:43 PM
    #13
    Wynnded

    Wynnded What MPG...

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    The permanent codes can't be reset. I have them as well with my Hewitt bypass, installed as a preventative measure. I'm not sure what to say about the limp mode, unless one of the valves is stuck open, which is something that you don't want...if your code is indeed P2440 or one of the other related ones.
     
  14. Aug 17, 2022 at 2:59 AM
    #14
    Roland

    Roland New Member

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    Hi,
    Thanks for the reply. Shouldn't the status of the valves & pumps be a non issue now that they are completely out of the system due to the bypass kit? I don't want to throw any more money at this but limp mode is almost a deal breaker. Do you think replacing the ECM would work to eliminate the permanent codes and get me out of limp mode prison?
    Thanks
    Chris
     
  15. Aug 17, 2022 at 5:08 AM
    #15
    Wynnded

    Wynnded What MPG...

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    Unfortunately no. The valves and pump are still in the system, all that the bypass does is fool the sensors into thinking that conditions are such that it's not necessary to run the pumps and open/close the valves; it also prevents an active CEL, but there will still be permanent codes as you and I both are seeing. If memory serves, I think my codes are for the valves being "stuck closed" as they never open due to installation of the bypass. As mentioned before, it's my understanding that you do not want to run the engine the valve are open. I'm not recalling details (and hopefully someone can chime in) but doing so will damage some pressure sensors or something. Getting a new ECU will not sort this, I suspect that you'll have to focus on those valves and what to replace to get them closed. I've not had to deal with this directly myself, so what I know is limited.
     
  16. Aug 17, 2022 at 6:15 AM
    #16
    Roland

    Roland New Member

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    Thanks.
    I also installed the additional pressure sensors from Hewitt which should have taken the Toyota valves out of the system all together, no?
     
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  17. Aug 17, 2022 at 6:41 AM
    #17
    Rsnake69

    Rsnake69 New Member

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    I been getting these codes for the last week. I order the gen 2 bypass kit this morning from Hewitt-tech
     
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  18. Aug 17, 2022 at 7:09 AM
    #18
    Roland

    Roland New Member

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    Do you have any permanent codes?
    Did you order the pressure sensor options?
    I didn't at first hoping that the bypass kit would solve the problem but it didn't.
    I just don't understand why, with the pumps and valves out of the system, that I still can't erase the codes! Don't know if I now need to get a new ECM.
     
  19. Aug 17, 2022 at 7:30 AM
    #19
    Rsnake69

    Rsnake69 New Member

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    I have code p2441 p2442. I ordered G22B57H1 gen 2. I will see what happens when I get it put on.
     
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  20. Aug 17, 2022 at 10:36 AM
    #20
    Wynnded

    Wynnded What MPG...

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    The codes are permanent.
    The problem is with the open valves, they can allow hot exhaust to an area where they cause damage (they're supposed to close early in the warm up cycle before the gases become too hot). The bypass cannot affect (open/close) the position of the valves themselves. They're really never out of the system (unless physically removed, an option), they're just not activated.

    Call Hewitt maybe, I talked with them when I purchased my bypass (years ago) and they seemed willing and able to explain what the device can and cannot do.
     
  21. Aug 17, 2022 at 10:53 AM
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    Leo's first

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    My gen 2 kit came with blocking plates tried just the plug-in bypass still got codes and limp mode after blocking plates installed all is well 5 yrs now
    Mine is the 5.7 one of the valves is stuck open
     
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  22. Aug 17, 2022 at 11:01 AM
    #22
    Wynnded

    Wynnded What MPG...

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    Aww heck man, it's been so long since I installed mine that I forgot all about the blocking plates! They're for cases where the valves are stuck open.
     
  23. Aug 19, 2022 at 2:37 AM
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    Roland

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    I've got the bypass kit, blocking plates and optional pressure sensors installed and still have codes and limp mode. I don't care about the permanent codes If I could get out of limp mode, but I can't. Do permanent codes block me from getting out of limp mode? My code reader doesn't seem to be able to erase any codes now, (current, temp, history or permanent) none. Could it be the ECM got damaged? Anybody ever replace their ECM?
    Thanks,
    Chris
     
  24. Aug 19, 2022 at 3:31 AM
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    Rsnake69

    Rsnake69 New Member

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    Unhook the battery for 10 minutes and see what happens.
     
  25. Aug 19, 2022 at 4:25 AM
    #25
    Roland

    Roland New Member

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    First thing I tried and didn't work.
     
  26. Aug 19, 2022 at 4:45 AM
    #26
    Wynnded

    Wynnded What MPG...

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    Not that I've heard, but I suppose that the right situation might keep your vehicle in limp mode. Also, there may be a code set due to a check that the ECU does as soon as you turn the key to RUN. Do you have codes in addition to the P2440? Maybe they could give some insight.
     
  27. Aug 19, 2022 at 4:58 AM
    #27
    Roland

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    Codes are 1201, 2433, 2445
     
  28. Aug 19, 2022 at 4:58 AM
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    Roland

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  29. Aug 19, 2022 at 10:47 AM
    #29
    Wynnded

    Wynnded What MPG...

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    P1201 - Cylinder #1 injector open/short circuit
    P2433 - Secondary Air Injection System Air Flow/Pressure Sensor Circuit High Bank 1
    P2445 - Secondary Air Injection System Pump Stuck Off Bank 1

    Any of these may be keeping you in Limp Mode, P1201 strikes me as being the most likely. I'm kinda surprised that there also aren't misfire codes for the same cylinder. Cause could be a bad injector or damaged wires.

    The other two shouldn't present any basic engine running malfunctions but would certainly set a CEL/codes; I don't think that the bypass would prevent those codes either. Not 100% though.
     
  30. Aug 19, 2022 at 3:40 PM
    #30
    Roland

    Roland New Member

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    Sorry, should have been more specific with the codes. The 1201 code is a C1201 not a P1201.
    Reader says C1201 Engine Control System Malfunction. Motor runs fine.
     

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