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. DTC Detection Condition Trouble Area
P2440 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

  • Vacuum hose (air switching valve - air pressure sensor)

  • Air injection hose

  • Air pressure sensor

  • Air pressure sensor circuit

  • Air Injection Control Driver

  • ECM

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.

Exhaust gas pulsation is detected by the air pressure sensor despite the ECM commanding the Air Switching Valve to close, the ECM interprets it as a malfunction of the secondary Air Injection system, and illuminates the MIL and sets a DTC.

WIRING DIAGRAM

Refer to the following pages.


INSPECTION PROCEDURE

Tech Tips


  • By using the intelligent tester 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 intelligent tester. 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 intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

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

    5. Read DTCs.

      Result
      Result Proceed to
      DTC P2440 is output A
      DTC P2440 and P0412 are output B
      DTC P2440 and other DTCs (except P0412) are output C

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


    B

    GO TO AIR SWITCHING VALVE INSPECTION PROCEDURE Click here

    C

    GO TO DTC CHART Click here

    A

  2. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (SECONDARY AIR INJECTION SYSTEM OPERATION)

    A00XC0V

    1. Perform a visual check


      1. Start the engine and warm it up.

      2. Turn the ignition switch off.

      3. Disconnect the No. 1 air injection system hose.

      4. Connect the intelligent tester to the DLC3.

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

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

        Tech Tips

        When Manual Mode is selected, the intelligent tester 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.

      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 intelligent tester is prohibited, the intelligent tester display indicates the prohibition (Wait or Error).

          If an Error is displayed on the intelligent tester 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 AIR 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.

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

      13. Reconnect the No. 1 air injection system hose.

    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 intelligent tester to the DLC3.

      4. Turn the ignition switch to ON and turn the tester 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.

      6. Start the engine after the intelligent tester 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 intelligent tester, 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
        NG A
        OK B

    B

    INSPECT VACUUM HOSES (AIR SWITCHING VALVE - AIR PRESSURE SENSOR) Click here

    A

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

    A00XHPYE01
    Text in Illustration
    *1 No. 4 Intake Pipe

    1. 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.

    NG

    REPLACE NO. 4 INTAKE PIPE

    OK

  4. INSPECT AIR SWITCHING VALVE ASSEMBLY (AIR SWITCHING VALVE OPERATION)


    1. Inspect the air switching valve assembly Click here.


    NG

    REPLACE AIR SWITCHING VALVE ASSEMBLY Click here

    OK

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

    A00XHMSE09
    Text in Illustration
    *a

    Front view of wire harness connector

    (to Air Injection Control Driver)

    1. 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
      A17-1 (BATT) - Body ground Ignition Switch ON 11 to 14 V (near battery voltage)
      A16-5 (+B) - Body ground Always 11 to 14 V (near battery voltage)

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

      Standard Resistance (Check for open)
      Tester Connection Condition Specified Condition
      A16-1 (E) - Body ground Always Below 1 Ω

    5. Reconnect the air injection control driver connectors.


    NG

    REPAIR OR REPLACE AIR INJECTION CONTROL DRIVER POWER SOURCE CIRCUIT

    OK

  6. PERFORM ACTIVE TEST USING INTELLIGENT TESTER

    A00XD6JE05
    Text in Illustration
    *a

    Component with wire harness connected

    (ECM)

    1. Start the engine and warm it up.

    2. Turn the ignition switch off.

    3. Connect the intelligent tester to the DLC3.

    4. Turn the ignition switch to ON.

    5. Turn the tester on.

    6. 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.

    7. Start the engine after the intelligent tester initialization is finished.

    8. Operate the secondary air injection system using the System Check function and measure the voltage between the terminals of the ECM connector.

    9. Turn the ignition switch off.

      Note


      • Do not perform the System Check operation repetitively. It may cause damage to 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 turned to ON or the engine running.

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

      Standard Voltage
      tester Operation Tester Connection Specified Condition
      AIR PUMP: ON, ASV: OPEN G59-6 (AIRV) - C64-5 (E1) 3.5 to 7.5 V
      AIR PUMP: OFF, ASV: CLOSE G59-6 (AIRV) - C64-5 (E1) 10 V or more

    NG

    CHECK HARNESS AND CONNECTOR (ECM - AIR INJECTION CONTROL DRIVER) Click here

    OK

  7. REPLACE AIR INJECTION CONTROL DRIVER


    1. Replace the air injection control driver Click here.


    NEXT

  8. CHECK WHETHER DTC OUTPUT RECURS (DTC P2440 AND/OR P2441)


    1. Start the engine and warm it up.

    2. Turn the ignition switch off.

    3. Connect the intelligent tester to the DLC3.

    4. Turn the ignition switch to ON.

    5. Turn the tester on.

    6. Clear DTCs (if set) Click here.

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

    8. Start the engine after the intelligent tester initialization is finished.

    9. Perform the System Check operation by pressing Next.

    10. After operating the secondary air injection system, perform the following to confirm the Secondary Air Injection system pending codes: Press the Exit button.

    11. Check pending DTCs.

    12. 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.


    NEXT

    END

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

    OK
    No blockage and no deformation in vacuum hose.

    NG

    REPAIR OR REPLACE VACUUM HOSE

    OK

  10. INSPECT AIR PRESSURE SENSOR


    1. A00XGSD

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

    2. Connect the intelligent tester to the DLC3.

    3. Turn the ignition switch to ON.

    4. Turn the tester on.

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

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

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

      Tech Tips

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


    NG

    REPLACE AIR PRESSURE SENSOR Click here

    OK

    CHECK FOR INTERMITTENT PROBLEMS Click here

  11. 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 (Check for open)
      Tester Connection Condition Specified Condition
      G59-6 (AIRV) - A16-3 (SIV) Always Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      G59-6 (AIRV) or A16-3 (SIV) - Body ground Always 10 kΩ or higher

    4. Reconnect the ECM connector.

    5. Reconnect the air injection control driver connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

    REPLACE ECM Click here