1. Welcome to Tundras.com!

    You are currently viewing as a guest! To get full-access, you need to register for a FREE account.

    As a registered member, you’ll be able to:
    • Participate in all Tundra discussion topics
    • Transfer over your build thread from a different forum to this one
    • Communicate privately with other Tundra owners from around the world
    • Post your own photos in our Members Gallery
    • Access all special features of the site

Secondary Air System / SAIS Replacement Info and Instructions

Discussion in '1st Gen Tundras (2000-2006)' started by wandering_boy, Jun 5, 2021.

  1. Jul 5, 2022 at 1:40 PM
    #31
    shifty`

    shifty` I might be an adult, I'm a minor at heart

    Joined:
    Jun 20, 2020
    Member:
    #48239
    Messages:
    9,167
    First Name:
    lowercase 'shifty'
    ATL
    Vehicle:
    '06 AC Limited 4WD + LSD & TOW PKG
    If I understand correctly, most or all of these kits simulate a healthy system, sending the "expected" inputs to the ECU. If your inspection is purely computer-based like it is here in GA, without any type of visual/tamper detection as part of the inspection, it should be invisible.

    It varies from state to state whether or not you'll have a more in-depth inspection. And there are varying levels of SAIS bypass kits ranging from "really damn obvious" to "extremely easy to conceal".

    Like, the 1st generation of the Hewitt kit, to me, is really easy on the install, but a trained inspector could probably find it if they knew what to look for. The 2nd Generation of the Hewitt kit is far more concealed, but requires popping out your dashboard and soldering onto 3 wires plugging into the ECU.

    Ultimately, YMMV. I think it depends on your level of comfort and the severity of your inspection. There's at least one, maybe two guys from CA on here who've installed the bypass kit and made it through the CA inspection process just fine.
     
    HewittTech01 likes this.
  2. Jul 8, 2022 at 4:16 PM
    #32
    2006Tundra

    2006Tundra New Member

    Joined:
    Jun 27, 2017
    Member:
    #8299
    Messages:
    629
    Gender:
    Male
    First Name:
    Luis
    Long Beach, CA
    Vehicle:
    06 Double Cab SR5 Toyota Tundra
    FrenchToasty likes this.
  3. Sep 29, 2022 at 6:27 AM
    #33
    HewittTech01

    HewittTech01 Dont Replace SAIS, Bypass It!

    Joined:
    Sep 21, 2022
    Member:
    #83702
    Messages:
    61
    Gender:
    Male
    Lexington, SC
    Vehicle:
    Secondary Air Injection System Bypass Kit
    Great Thread and hats off to @wandering_boy for detailed replacement documentation! My only input would be if you do the repair and go through all the effort to remove the intake please please please use Factory/OEM parts. Aftermarket Parts are cheap for a reason and see way to many owner cut this corner and end up paying more in the long run. If anyone has questions about the Bypass Please do not hesitate to contact us.
     
    Leo's first and Tundra2 like this.
  4. Sep 30, 2022 at 6:45 PM
    #34
    wandering_boy

    wandering_boy [OP] Junior Tech Wizard

    Joined:
    Feb 27, 2019
    Member:
    #26790
    Messages:
    400
    Gender:
    Male
    First Name:
    Jason
    California
    Vehicle:
    2005 AC SR5 TRD
    Don't let a kid out smart you.
    All switching valves and the pump were from Toyota and GM direct. I feel like for the rubber intake gasket is a OE replacement. No Cheap stuff here. But absolutely a good tip for anyone who does this. Thanks for the input. always trying to make my instructions better. If you have a good link about bypassing besides what I have. Please feel free to PM with them.
     
    HewittTech01[QUOTED] likes this.
  5. Sep 30, 2022 at 6:50 PM
    #35
    wandering_boy

    wandering_boy [OP] Junior Tech Wizard

    Joined:
    Feb 27, 2019
    Member:
    #26790
    Messages:
    400
    Gender:
    Male
    First Name:
    Jason
    California
    Vehicle:
    2005 AC SR5 TRD
    Don't let a kid out smart you.
    You still pass smog but since technically it is an emissions control device. So it does technically legally make it unsellable as a smog-able vehicle. I can't remember what the code is but its either in the carb or CA dot Codes. But it passes and I certainly don't don't give a F. So why tell the next dude.
     
  6. Oct 1, 2022 at 10:43 AM
    #36
    Shift Happens

    Shift Happens New Member

    Joined:
    Oct 1, 2022
    Member:
    #84200
    Messages:
    7
    Gender:
    Male
    Vehicle:
    2002 SR5 AC TRD
    Lol, catching up on all the things that haven't been addressed.
    So, I want to verify I am reading all this correctly, an 02 does NOT have the air pump or any of these valves, right?

    I am chasing down a vacuum leak that makes a high pitched whistle, and it is a pain... replaced most of my hoses with off the shelf tubing and tried to seal the ends up on the tubes that are factory bent and flared that I will need to order.

    I have a question if anyone can help out with these specific symptoms: on start and when running, a high pitched reedy whistle sound is heard, cannot find source or pinpoint which side of engine but *seems* like drivers side. When I pinch or jiggle vacuum lines on either side of engine, the noise will subside or stop temporarily. Revving engine seems to reduce it or eliminate it until I let off gas but it could just be drowning it out. Whistle persists for about 10 sec after turning engine off.

    Any help would be greatly appreciated.
     
  7. Oct 1, 2022 at 11:20 AM
    #37
    shifty`

    shifty` I might be an adult, I'm a minor at heart

    Joined:
    Jun 20, 2020
    Member:
    #48239
    Messages:
    9,167
    First Name:
    lowercase 'shifty'
    ATL
    Vehicle:
    '06 AC Limited 4WD + LSD & TOW PKG
    Correct, '05-'06 only, VVT-i models.

    Quite likely intake manifold. Let's ask @bmf4069 since he's already gone through this with his and described very similar symptoms IIRC.

    Only use OEM manifold gasket. Trust on this.
     
    bmf4069 likes this.
  8. Oct 1, 2022 at 11:45 AM
    #38
    Shift Happens

    Shift Happens New Member

    Joined:
    Oct 1, 2022
    Member:
    #84200
    Messages:
    7
    Gender:
    Male
    Vehicle:
    2002 SR5 AC TRD
    Lol, catching up on all the things that haven't been addressed.
    Intake manifold? That is something I have not considered yet. I have been eyeing the charcoal canister as the culprit, but this helps, thank you.

    Is that gasket fairly simple? Or is it more like a valve cover gasket (which I need to do sometime and have been reading about)?
     
  9. Oct 1, 2022 at 1:03 PM
    #39
    bmf4069

    bmf4069 Yup, that's car parts in a dishwasher

    Joined:
    Sep 1, 2018
    Member:
    #18880
    Messages:
    5,388
    Gender:
    Male
    TX
    Vehicle:
    02 AC sr5 4wd v8
    Mine was backfiring pretty bad, but my gasket was completley blown out. @Shift Happens it wouldn't hurt to try to listen under the intake. It's very possible your gasket is bad.

    20211126_153853.jpg

    20211126_153858.jpg

    20211126_153908.jpg

    As @shifty` said, OEM would be best. This gasket was from RA and is maybe a year or 2 old.
     
  10. Oct 1, 2022 at 1:54 PM
    #40
    shifty`

    shifty` I might be an adult, I'm a minor at heart

    Joined:
    Jun 20, 2020
    Member:
    #48239
    Messages:
    9,167
    First Name:
    lowercase 'shifty'
    ATL
    Vehicle:
    '06 AC Limited 4WD + LSD & TOW PKG
    Oof. Man, I don't think I knew that part of it. Yikes!
     
  11. Nov 14, 2022 at 3:21 PM
    #41
    HBTundra

    HBTundra New Member

    Joined:
    Nov 20, 2019
    Member:
    #38908
    Messages:
    578
    Gender:
    Male
    Vehicle:
    2006 DC 2wd
    So I've had my CEL going on & off since installing the bypass kit.
    Hewitt has been 100% solid on customer service, . . . I'm the one who has been lagging and not getting back into the harness to triple check my connections.
    I suspect I left too much slack in the bypass harness when I soldered up the wires.
    Light comes on for a day or so, then goes off for a couple weeks. Weird.
    So my smog cert was due, and the light CEL was 'off' so I said, F-It and went for it . . . passed just fine.
    I'll report back when I get off my arse & take another look at the connections & take some of the slack out of the wires.
     
    wandering_boy[OP] and 2006Tundra like this.
  12. Nov 17, 2022 at 7:52 AM
    #42
    tokolosh

    tokolosh Serial procrastinator

    Joined:
    May 20, 2021
    Member:
    #63313
    Messages:
    115
    Gender:
    Male
    First Name:
    J
    SF Bay Area
    Vehicle:
    05 AC V8 SR5 Phantom Grey
    new driver
    So dumb question for y'all...

    It appears all this is to correct codes caused by the SAIS system failure. If I have no issues do I just run it till I do or is there some preventative stuff I should be doing?
     
  13. Nov 17, 2022 at 11:38 AM
    #43
    HBTundra

    HBTundra New Member

    Joined:
    Nov 20, 2019
    Member:
    #38908
    Messages:
    578
    Gender:
    Male
    Vehicle:
    2006 DC 2wd
    There is nothing you can do preventatively to avoid an SAIS failure.
    However, I seem to remember that in 'certain scenarios' one (or more) of the switching valves/ solenoids can get stuck in an open or closed configuration, which requires you to add an additional component to the Hewitt bypass kit after the fact.
    I know this is a 'vague reply' , maybe someone else will jump in and explain it better.

    I know this sounds ridiculous, but a 'safer' way to avoid the problem is to install the bypass kit before the system itself fails in the first place.
    Yep, fixing something that isn't broke . . . . Yet.
     
  14. Nov 17, 2022 at 11:42 AM
    #44
    2006Tundra

    2006Tundra New Member

    Joined:
    Jun 27, 2017
    Member:
    #8299
    Messages:
    629
    Gender:
    Male
    First Name:
    Luis
    Long Beach, CA
    Vehicle:
    06 Double Cab SR5 Toyota Tundra
  15. Nov 17, 2022 at 11:59 AM
    #45
    Leo's first

    Leo's first TRUCK GANG

    Joined:
    Sep 6, 2017
    Member:
    #9490
    Messages:
    4,985
    Gender:
    Male
    First Name:
    Mike
    Groton ma
    Vehicle:
    2007 Tundra Limited CM Pyrite Mica
    Yep if one of your valves sticks open you have to install blocking plates on the exhaust manifold at least on my 07 not sure on 06
    also stuck open valve puts truck in limp mode so you have to repair or bypass
     
  16. Nov 28, 2022 at 5:39 PM
    #46
    wandering_boy

    wandering_boy [OP] Junior Tech Wizard

    Joined:
    Feb 27, 2019
    Member:
    #26790
    Messages:
    400
    Gender:
    Male
    First Name:
    Jason
    California
    Vehicle:
    2005 AC SR5 TRD
    Don't let a kid out smart you.
    Unfortunately there is no maintenance for your SAIS. You just have to wait until it shits the bed. Unless you want to proactively replace things. The check valves that connect to the headers are the most common problem as the heat of the exhaust causes everything to rust up. Nothing you can do about that. It's just a law of chemistry.
     
    tokolosh[QUOTED] likes this.
  17. Nov 28, 2022 at 5:42 PM
    #47
    shifty`

    shifty` I might be an adult, I'm a minor at heart

    Joined:
    Jun 20, 2020
    Member:
    #48239
    Messages:
    9,167
    First Name:
    lowercase 'shifty'
    ATL
    Vehicle:
    '06 AC Limited 4WD + LSD & TOW PKG
    The trick is, just don't make the mistake of studying chem like I did. Ignorance is bliss.

     
  18. Nov 28, 2022 at 5:47 PM
    #48
    wandering_boy

    wandering_boy [OP] Junior Tech Wizard

    Joined:
    Feb 27, 2019
    Member:
    #26790
    Messages:
    400
    Gender:
    Male
    First Name:
    Jason
    California
    Vehicle:
    2005 AC SR5 TRD
    Don't let a kid out smart you.
    I've only done high school chem and basic chem in college. It has ruined my life. lol
     
  19. Nov 28, 2022 at 5:54 PM
    #49
    shifty`

    shifty` I might be an adult, I'm a minor at heart

    Joined:
    Jun 20, 2020
    Member:
    #48239
    Messages:
    9,167
    First Name:
    lowercase 'shifty'
    ATL
    Vehicle:
    '06 AC Limited 4WD + LSD & TOW PKG
    Full year of chemistry in high school, a couple semesters of inorganic chem in college. It was literally the only thing I enjoyed in college before taking 'a semester off'. College wasn't for me.
     
  20. Jan 6, 2023 at 1:14 PM
    #50
    HewittTech01

    HewittTech01 Dont Replace SAIS, Bypass It!

    Joined:
    Sep 21, 2022
    Member:
    #83702
    Messages:
    61
    Gender:
    Male
    Lexington, SC
    Vehicle:
    Secondary Air Injection System Bypass Kit
    Well said and pardon I am late to the dance. As you will see plastered all over the forum and inter webs the SAIS is Failure Prone. There are a few advantages to installing the Bypass Kit as a preventative measure. First, there are certain SAIS error codes that will put the truck into Limp Mode, specifically "Valve Stuck Open" fault codes P2440 2442. When the truck goes into Limp Mode your performance and acceleration will be governed and luck to get up to 35 MPH. This would be terrible if you take long trips with your truck, travel off road or regularly tow. Second, if the truck is driven for long duration or you repeatedly clear the codes this expose the Pressure Sensor Inside the Air Switching Valve to exhaust. Exhaust can damage the Pressure Sensor. The Bypass Kit require the Pressure Sensor to be in good working condition to operate as engineered. In the event of Pressure Sensor damage then Addons to the Bypass Kit will be needed to clear codes.

    So you can wait to the SAIS components fail and install the Bypass Kit. Or save your self some trouble and install proactively. Below I have included a few thread we posted about the SAIS and our Bypass Kit. Do not hesitate to contact us if you have any questions.

    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/
     
    2006Tundra and HBTundra[QUOTED] like this.

Products Discussed in

To Top