SFI SYSTEM, Diagnostic DTC:P2440

DTC Code DTC Name
P2440 Secondary Air Injection System Switching Valve Stuck Open Bank1

DESCRIPTION

Refer to DTC P2431.

Click here

DTC No. Detection Item DTC Detection Condition Trouble Area MIL Memory
P2440 Secondary Air Injection System Switching Valve Stuck Open Bank1 Air pressure sensor detects pulsation of exhaust gas despite ECM commanding air switching valve to close, while engine running (1 trip detection logic)

  • Air switching valve

  • Open or short in air switching valve circuit

  • Air pressure sensor

  • Air pressure sensor circuit

  • Air injection control driver

  • ECM

  • FUEL PMP/AIR PMP HTR relay

 Comes on DTC stored

Tech Tips

Air switching valve normal operation:

When the air switching valve is open, exhaust gas pulsation occurs in the secondary air passage.

When the air switching valve is closed, exhaust gas pulsation does not occur in the secondary air passage.

MONITOR DESCRIPTION

Air switching valve of the secondary air injection system.

If either of the following conditions occurs, the ECM interprets it as a malfunction of the secondary air injection system, and illuminates the MIL and stores a DTC:


MONITOR STRATEGY

Required Sensors/Components Air pressure sensor
Frequency of Operation Once per drive cycle

TYPICAL MALFUNCTION THRESHOLDS

P2440 Air valve is stuck open:
P2440 Air valve is stuck open -
One of the following conditions is met A or B
A: Conditions 1 (AIR OFF) (Case1) -
B: Cumulative pressure pulsation (Case2) 80 kPa (600.05 mmHg) or higher

Tech Tips

Refer to "Data List / Active Test" [Air Pump Pressure (Absolute) and Air Pump Pulsation Pressure].

Click here

CONFIRMATION DRIVING PATTERN

Tech Tips


  • This Secondary Air Injection Check only allows technicians to operate the secondary air injection system for a maximum of 5 seconds.

    Furthermore, the check can only be performed up to 4 times per trip. If the test is repeated, intervals of at least 30 seconds are required between checks.

    While secondary air injection system operation using the GTS is prohibited, the GTS display indicates the prohibition (WAIT or ERROR).

    If ERROR is displayed on the GTS during the test, stop the engine for 10 minutes, and then try again.

  • Performing the Secondary Air Injection Check repeatedly may cause damage to the secondary air injection system. If necessary, leave an interval of several minutes between System Check operations to prevent the system from overheating.

  • When performing the Secondary Air Injection Check operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch turned to ON or the engine running.

  • Turn the ignition switch off when the Secondary Air Injection Check operation finishes.


  1. Start the engine and warm it up.

  2. Turn the ignition switch off.

  3. Connect the GTS to the DLC3.

  4. Turn the ignition switch to ON and turn the GTS on.

  5. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).

  6. Turn the ignition switch off and wait for at least 30 seconds.

  7. Turn the ignition switch to ON and turn the GTS on.

  8. Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Automatic Mode.

  9. Start the engine after the GTS initialization is finished.

  10. Perform the System Check operation by pressing Next.

  11. Perform the following to confirm the secondary air injection system pending DTCs: Press Exit button.

  12. Check for pending DTCs.

    Tech Tips


    • If a pending DTC is output, the system is malfunctioning.

    • If a pending DTC is not output, perform the following procedure.

  13. After the "Air injection check" is completed, check for All Readiness by entering the following menus: Powertrain / Engine and ECT / Utility / All Readiness.

  14. Input the DTC: P2440.

  15. Check the DTC judgment result.

    GTS Display Description
    NORMAL

    • DTC judgment completed

    • System normal
    ABNORMAL

    • DTC judgment completed

    • System abnormal
    INCOMPLETE

    • DTC judgment not completed

    • Perform driving pattern after confirming DTC enabling conditions
    N/A

    • Unable to perform DTC judgment

    • Number of DTCs which do not fulfill DTC preconditions has reached ECU memory limit

    Tech Tips


    • If the judgment result shows NORMAL, the system is normal.

    • If the judgment result shows ABNORMAL, the system has a malfunction.

    • If the judgment result shows INCOMPLETE or N/A, perform the Confirmation Driving Pattern and check the DTC judgment result again.

WIRING DIAGRAM

Refer to the following pages.


CAUTION / NOTICE / HINT

Tech Tips


  • By using the GTS to perform the Secondary Air Injection Check operation in the System Check, the air fuel ratio and the pressure in the secondary air injection system passage can be checked while the secondary air injection system is operating. This helps technicians to troubleshoot the system when it malfunctions. Furthermore, Pending Codes also can be checked by performing Utility / Secondary Air Injection Check / Automatic Mode after the repair.

  • Read freeze frame data using the GTS. Freeze frame data records the engine condition when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.

PROCEDURE


  1. CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO SECONDARY AIR INJECTION SYSTEM DTCS)


    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the GTS on.

    4. Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.


      Powertrain > Engine > Trouble Codes

    5. Read DTCs.

      Result
      Result Proceed to
      DTC P2440 is output (for w/ air pump heater) A
      DTC P2440 is output (for w/o air pump heater) B
      DTC P2440 and P0412 are output C
      DTC P2440 and other DTCs (except P0412) are output D

      If any DTCs other than P2440 are output, troubleshoot those DTCs first.


    B

    INSPECT AIR PUMP ASSEMBLY Click here

    C

    GO TO AIR SWITCHING VALVE INSPECTION PROCEDURE Click here

    D

    GO TO DTC CHART Click here

    A

  2. CHECK FREEZE FRAME DATA (AIR PUMP FREEZE AND AIR SWITCHING VALVE FREEZE)


    1. Connect the GTS to the DLC3.

    2. Turn the ignition switch to ON and turn the GTS on.

    3. Read the values of Air Pump Freeze and Air Switching Valve Freeze from the freeze frame data recorded previously.

    4. Referring to the following table, proceed to the appropriate step according to the result of the data reading.

      Result
      Result Proceed to
      Air Pump Freeze Air Switching Valve Freeze
      OFF OFF A
      Except above B

    B

    GO TO STEP 8 Click here

    A

  3. PERFORM ACTIVE TEST USING GTS (ACTIVATE THE AIR PUMP HEATER)


    1. B003QKZC01
      *a

      Front view of wire harness connector

      (to Air Pump Assembly)

      Disconnect the air pump connector.

    2. Connect the GTS to the DLC3.

    3. Turn the ignition switch to ON and turn the GTS on.

    4. Enter the following menus: Powertrain / Engine and ECT/ Active Test / Activate the Air Pump Heater.

    5. Measure the voltage according to the value(s) in the table below.

      Standard Voltage
      Tester Connection Condition Specified Condition
      A76-1 (APH+) - Body ground Activate the Air Pump Heater is ON 11 to 14 V
      Result
      Proceed to
      OK
      NG

    NG

    INSPECT FUEL PMP/AIR PMP HTR RELAY Click here

    OK

  4. INSPECT AIR PUMP ASSEMBLY (HEATER RESISTANCE)


    1. Inspect the air pump assembly.

      Click here

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE AIR PUMP ASSEMBLY Click here

    OK

  5. INSPECT FUEL PMP/AIR PMP HTR RELAY


    1. Inspect the FUEL PMP/AIR PMP HTR relay.

      Click here

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE FUEL PMP/AIR PMP HTR RELAY

    OK

  6. CHECK HARNESS AND CONNECTOR (FUEL PMP/AIR PMP HTR RELAY - BATTERY)


    1. Remove the FUEL PMP/AIR PMP HTR relay from the engine room relay block and junction block assembly.

    2. Disconnect the cable from the negative (-) battery terminal.

    3. Disconnect the cable from the positive (+) battery terminal.

    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      FUEL PMP/AIR PMP HTR relay terminal 2 - Battery positive (+) terminal Always Below 1 Ω
      FUEL PMP/AIR PMP HTR relay terminal 2 or Battery positive (+) terminal - Body ground Always 10 kΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  7. CHECK HARNESS AND CONNECTOR (FUEL PMP/AIR PMP HTR RELAY - AIR PUMP)


    1. Remove the FUEL PMP/AIR PMP HTR relay from the engine room relay block and junction block assembly.

    2. Disconnect the air pump connector.

    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      FUEL PMP/AIR PMP HTR relay terminal 3 - A76-1 (APH+) Always Below 1 Ω
      A76-3 (APHG) - Body ground Always Below 1 Ω
      FUEL PMP/AIR PMP HTR relay terminal 3 or A76-1 (APH+) - Body ground Always 10 kΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  8. INSPECT AIR PUMP ASSEMBLY


    1. Inspect the air pump assembly

      Click here

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE AIR PUMP ASSEMBLY Click here

    OK

  9. PERFORM ACTIVE TEST USING GTS (SECONDARY AIR INJECTION SYSTEM OPERATION)


    1. B003PRX

      Perform a visual check.


      1. Start the engine and warm it up.

      2. Turn the ignition switch off.

      3. Disconnect the air hose No. 6.

      4. Connect the GTS to the DLC3.

      5. Turn the ignition switch to ON and turn the GTS on.

      6. Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Manual Mode / AIR PUMP: ON, ASV: OPEN.


        Powertrain > Engine > Utility
        Tester Display
        Secondary Air Injection Check

        Tech Tips

        When Manual Mode is selected, the GTS initialization (atmospheric pressure measurement) is performed automatically. The initialization takes 10 seconds. After the initialization, AIR PUMP and ASV operation can be selected.

      7. Start the engine.

      8. Perform the secondary air injection system intrusive operation while the engine is idling.

      9. Place your hand near the air switching valve port and check that the exhaust gas pressure pulsates when the ASV is turned on.

        CAUTION:

        To avoid the danger of being burned by the exhaust gas, bring your hand close to the valve port slowly.

      10. Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Manual Mode / AIR PUMP: ON, ASV: CLOSE.


        Powertrain > Engine > Utility
        Tester Display
        Secondary Air Injection Check

      11. Check that the exhaust gas does not pulsate when the ASV is turned off.

      12. Turn the ignition switch off.

        Note


        • This secondary air injection Check only allows technicians to operate the AIR system for a maximum of 5 seconds. Furthermore, the check can only be performed up to 4 times per trip. If the test is repeated, intervals of at least 30 seconds are required between checks.

          While secondary air injection system operation using the GTS is prohibited, the GTS display indicates the prohibition (WAIT or ERROR).

          If ERROR is displayed on the GTS during the test, stop the engine for 10 minutes, and then try again.

        • When performing the Secondary Air Injection Check operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch turned to ON or the engine running.

        • Turn the ignition switch off when the Secondary Air Injection Check operation finishes.

        OK
        Air Pump Operation ASV Operation Exhaust Gas Pulsation
        ON OFF Not detected
        ON ON Detected

      13. Reconnect the air hose No. 6.

    2. Other inspection method:

      The air switching valve operation can be confirmed by checking the cumulative pressure pulsation* provided in the System Check.

      Perform System Check operation under Manual Mode.

      *: The exhaust pulsation value is calculated in the ECM.

      If the calculated value exceeds a certain level, the ECM determines that the exhaust pulsation is in the secondary air injection system.


      1. Start the engine and warm it up.

      2. Turn the ignition switch off.

      3. Connect the GTS to the DLC3.

      4. Turn the ignition switch to ON and turn the GTS on.

      5. Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Manual Mode / AIR PUMP: ON, ASV: OPEN and AIR PUMP: OFF, ASV: CLOSE.


        Powertrain > Engine > Utility
        Tester Display
        Secondary Air Injection Check

      6. Start the engine after the GTS initialization is finished.

      7. Perform the secondary air injection system intrusive operation while the engine is idling.

      8. Check that the air-fuel ratio and pressure in the secondary air injection system passage (PULSATION) displayed on the GTS, indicate the conditions shown in the table below.

      9. Turn the ignition switch off.

      Standard
      Secondary Air Injection System Operation

      Pulsation Condition

      (ECM Calculation)

      Air-Fuel Ratio

      (Reference)
      AIR PUMP: ON, ASV: OPEN 11.25 kPa or more 18 or more
      AIR PUMP: OFF, ASV: CLOSE Less than 11.25 kPa

      Approximately 14.5

      (around stoichiometric air-fuel ratio)
      Result
      Result Proceed to
      OK A
      NG B

      Tech Tips

      REFERENCE:

      If the air pump operation is confirmed as normal, the air-fuel ratio detected in front of three-way catalytic converter changes in response to the secondary air pumped into the exhaust port when the air pump operates.

      Click here


    B

    INSPECT NO. 4 INTAKE PIPE (BLOCKAGES AND LEAKAGES) Click here

    A

  10. INSPECT VACUUM HOSES (AIR SWITCHING VALVE - AIR PRESSURE SENSOR)

    OK
    No blockage and no deformation in vacuum hose.
    Result
    Proceed to
    OK
    NG

    NG

    REPAIR OR REPLACE VACUUM HOSE

    OK

  11. INSPECT AIR PRESSURE SENSOR


    1. B003OSW

      Connect a pressure gauge to the air pressure sensor as shown in the illustration.

    2. Connect the GTS to the DLC3.

    3. Turn the ignition switch to ON.

    4. Turn the GTS on.

    5. Enter the following menus: Powertrain / Engine and ECT / Data List / Air Pump Pressure (Absolute).

    6. Check that the pressure displayed on the GTS fluctuates when applying the pressure to the air pressure sensor with the pressure gauge.

      OK
      Pressure fluctuates in response to pressure applied with pressure gauge.

      Tech Tips

      The GTS displays the air pump pressure (Air Pump Pressure (Absolute)) as absolute pressure.

      Result
      Proceed to
      OK
      NG

    OK

    CHECK FOR INTERMITTENT PROBLEMS Click here

    NG

    REPLACE AIR PRESSURE SENSOR Click here

  12. INSPECT NO. 4 INTAKE PIPE (BLOCKAGES AND LEAKAGES)


    1. B003P9Z

      Check that the No. 4 intake pipe is securely connected to both the exhaust manifold and the air switching valve.

    2. Inspect the No. 4 intake pipe for blockages and damage.

      OK
      No blockages or damage on No. 4 intake pipe.
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE NO. 4 INTAKE PIPE

    OK

  13. INSPECT AIR SWITCHING VALVE ASSEMBLY


    1. Inspect the air switching valve assembly.

      Click here

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE AIR SWITCHING VALVE ASSEMBLY Click here

    OK

  14. INSPECT AIR INJECTION CONTROL DRIVER (POWER SOURCE OF AIR INJECTION CONTROL DRIVER)


    1. B003OZRC06
      *a

      Front view of wire harness connector

      (to Air Injection Control Driver)

      Disconnect the air injection control driver connectors.

    2. Turn the ignition switch to ON.

    3. Measure the voltage according to the value(s) in the table below.

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      A74-1 (BATT) - Body ground Always 11 to 14 V (near battery voltage)
      C142-5 (+B) - Body ground Ignition switch ON 11 to 14 V (near battery voltage)

    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      C142-1 (E) - Body ground Always Below 1 Ω
      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE AIR INJECTION CONTROL DRIVER POWER SOURCE CIRCUIT

    OK

  15. CHECK HARNESS AND CONNECTOR (ECM - AIR INJECTION CONTROL DRIVER)


    1. Disconnect the ECM connector.

    2. Disconnect the air injection control driver connector.

    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      G143-5 (AIRV) - C142-3 (SIV) Always Below 1 Ω
      G143-5 (AIRV) or C142-3 (SIV) - Body ground Always 10 kΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  16. PERFORM ACTIVE TEST USING GTS


    1. Disconnect the air injection control driver connector.

    2. B003OG4C34
      *1 Air Injection Control Driver
      *2 ECM
      *a

      Front view of wire harness connector

      (to Air Injection Control Driver)

      Connect terminals DI and SIV of the wire harness connector for the air injection control driver.

    3. Connect the GTS to the DLC3.

    4. Turn the ignition switch to ON.

    5. Turn the GTS on.

    6. Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Manual Mode / AIR PUMP: ON, ASV: OPEN.


      Powertrain > Engine > Utility
      Tester Display
      Secondary Air Injection Check

      Tech Tips

      When Manual Mode is selected, the GTS initialization (atmospheric pressure measurement) is performed automatically. The initialization takes 10 seconds. After the initialization, AIR PUMP and ASV operation can be selected.

    7. Start the engine.

    8. Perform the secondary air injection system intrusive operation while the engine is idling.

    9. Measure the voltage between the SIV and E terminals of the ECM connector when the secondary air injection system is on and off.

    10. Turn the ignition switch off.

      Note


      • Do not perform the System Check operation repeatedly as it may cause the damage in the system. If necessary, leave an interval of several minutes between System Check operations.

      • When performing the Secondary Air Injection Check operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch ON or the engine running.

      • Turn the ignition switch off when the Secondary Air Injection Check operation finishes.

      Standard Voltage
      Tester Connection Condition Specified Condition
      C142-3 (SIV) - C142-1 (E) AIR PUMP: ON, ASV: OPEN 0.5 to 2 V
      AIR PUMP: OFF, ASV: CLOSE 11 to 14 V
    11. B003OG4C35
      *1 Air Injection Control Driver
      *2 ECM
      *a

      Front view of wire harness connector

      (to Air Injection Control Driver)

      Connect terminals DI and SIP of the wire harness connector for the air injection control driver.

    12. Connect the GTS to the DLC3.

    13. Turn the ignition switch to ON.

    14. Turn the GTS on.

    15. Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Manual Mode / AIR PUMP: ON, ASV: OPEN.


      Powertrain > Engine > Utility
      Tester Display
      Secondary Air Injection Check

      Tech Tips

      When Manual Mode is selected, the GTS initialization (atmospheric pressure measurement) is performed automatically. The initialization takes 10 seconds. After the initialization, AIR PUMP and ASV operation can be selected.

    16. Start the engine.

    17. Perform the secondary air injection system intrusive operation while the engine is idling.

    18. Measure the voltage between the SIP and E terminals of the ECM connector when the secondary air injection system is on and off.

    19. Turn the ignition switch off.

      Note


      • Do not perform the System Check operation repeatedly as it may cause the damage in the system. If necessary, leave an interval of several minutes between System Check operations.

      • When performing the Secondary Air Injection Check operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch ON or the engine running.

      • Turn the ignition switch off when the Secondary Air Injection Check operation finishes.

      Standard Voltage
      Tester Connection Condition Specified Condition
      C142-4 (SIP) - C142-1 (E) AIR PUMP: ON, ASV: OPEN 0.5 to 2 V
      AIR PUMP: OFF, ASV: CLOSE 11 to 14 V
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE ECM Click here

    OK

  17. REPLACE AIR INJECTION CONTROL DRIVER


    1. Replace the air injection control driver.

      Click here

      Result
      Proceed to
      NEXT

    NEXT

  18. CHECK WHETHER DTC OUTPUT RECURS (DTC P2440)


    1. Start the engine and warm it up.

    2. Turn the ignition switch off.

    3. Connect the GTS to the DLC3.

    4. Turn the ignition switch to ON.

    5. Turn the GTS on.

    6. Clear DTCs (if stored).

    7. Turn the ignition switch off and wait for at least 30 seconds.

    8. Turn the ignition switch to ON.

    9. Enter the following menus: Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Automatic Mode.


      Powertrain > Engine > Utility
      Tester Display
      Secondary Air Injection Check

    10. Start the engine after the GTS initialization is finished.

    11. Perform the System Check operation by pressing Next.

    12. After operating the secondary air injection system, perform the following to confirm the secondary air injection system pending codes: Press the Exit button.

    13. Check pending DTCs.

    14. Turn the ignition switch off.

      OK
      No pending DTC output.

      Note


      • When performing the Secondary Air Injection Check operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch turned to ON or the engine running.

      • Turn the ignition switch off when the Secondary Air Injection Check operation finishes.

      Result
      Proceed to
      OK
      NG

    OK

    END

    NG

    REPLACE ECM Click here