Secondary Air Injection System Control Valve Stuck Closed - Bank 1 - Page 2

Justme · #16 (**permalink**) 04-26-2006, 11:15 PM

If I still have the problem when I get it back, going back to the factory intake system would be a 10 minute operation. No problem there. Going back to factory exhaust IS a problem. The magnaflow was welded in place and I didn't keep the factory muffler. It took me close to 12 hours to put those headers on, and my hands have not fully recovered from all the cuts from last time either!

So, I hope this isn't the last option...

Speaking of which, 05Tundra, just exactly where did you get that special tool you have in your profile? Think it would be great to have even if I keep the headers to retorque in the future. Is that a racketing box wrench of some kind?

I'm inclined to believe Victor that this is a problem because of the headers but I still don't understand if '100's' have been installed, why so very little have experienced this problem.

05Limited · #17 (**permalink**) 04-27-2006, 12:07 AM

See the pic below... I bought this at a local home center called OSH that sell craftsman tools. You should be able to pick up a set at Sears or even off of ebay. I think it was <$20 for the set. The other socket was a chopped down deep socket using a hacksaw or a chopsaw to ~<2".

Craftsman 14mm Wrench Socket use a ~25/64 bit to drill the center out.

Craftsman 8 pc. Wrench Socket Set, Metric

Craftsman 8 pc. Wrench Set, 12 pt. Combination Metric

So far I've put ~150 miles on the truck since the reset and no MIL yet. I'll try starting it up early in the morning.

Justme · #18 (**permalink**) 04-27-2006, 05:35 PM

Dealership called and said they confirmed that the air switching value needs to be replaced. Of course, they don't have one and hope to get it tomorrow. But he also said it may be Monday before it gets completed. They gave me a rental (Camary) so I have wheels but it just isn't the same!

mustang67408 · #19 (**permalink**) 04-27-2006, 05:51 PM

Got my fingers and toes crossed for both of ya.

05Limited · #20 (**permalink**) 04-27-2006, 07:30 PM

I hope it works... please update us after you get the truck back and put some miles on it. It took 2 days or so after getting it back for the MIL light to come back on.

I'm still waiting on my MIL light to pop a pretty yellow. It's been pretty warm here in SJC lately. hummm... maybe the light bulb is burned out for being on for so long.

Justme · #21 (**permalink**) 04-29-2006, 01:00 AM

Dealer called this afternoon and said my truck would be ready at the end of the day! He went on to say that they did so much dianostics with the engine off that they completely discharged my battery so they are going to replace it for free under warrenty. Not complaining, but this really is odd, no?

Anyway, picked it up and all is well so far. Put about 40 miles on it this evening with several stops and no CEL!! But the real test comes in the morning.

It still bothers me what exactly is the cause of this issue. Did the headers have any effect? 05Limited mentioned that JBA believes Toyota is going to issue an recall for the "diverter valve". I believe they really mean the switching value. Does this mean that others have had this problem without the installation of headers? Think I will ask this in the Tundra forum. Will post back in a day or two to comfirm if I have any other problems!

BTW, a big public thanks to Mustang67408 (Victor) and 05Limited for thier help and encouragement through this ordeal. I hope 05Limited problem has cleared itself as well!

Justme · #22 (**permalink**) 05-01-2006, 04:00 AM

Two and 1/2 days and all is well!

Not going to claim victory yet but I'm feeling better about it with each passing day. I asked in the Tundra forum if anyone has encounter this same issue, regardless if headers were involved and no one replied.

Figured if Toyota was going to issue an recall, someone else would have mentioned having the same issue. Oh well, I'm just glad that so far, no more CEL's!

BTW, 05Limited, what is the latest with your truck? Still no light?

05Limited · #23 (**permalink**) 05-01-2006, 12:19 PM

Interesting enough, I've put only ~220 miles since last week. ... the CEL hasn't come back on yet.

This morning was 61F when I started it. If it doesn't come back on then great!

I was kinda hoping it would. Maybe I'll have to wait till next winter for it to show up again. I'll claim victory if no light comes one by the next fill up or two.

If there was to be a recall, I would think many more people would have the issue too. Then again, not every tundra owner is on these forums or have headers that seem to amplify the faulty switching valves. BTW, I'm still glad to have these headers. Now with the CEL light off, I can finally go dyno my truck again.

Justme, thanks for posting your updates.

mustang67408, thanks for your help!

mustang67408 · #24 (**permalink**) 05-02-2006, 12:06 AM

Your both very welcome

I am glad i was wrong and ITS NOT the headers (knock on wood).
I will ask in a few weeks when I got to school if there is a TSB coming out dealing with the air injection, and try to get some more info on what makes it tick. How cold temps affect it and if there is anyting we can do to change it.
TS ROCKS!!

05Limited · #25 (**permalink**) 05-06-2006, 01:32 AM

Well, the CEL came on yesterday.

It was about 60F and I didn't let the engine warm up before taking off. I almost got a full tank without the light coming on. Bummer.... so I took it in today to the dealer the tech said the switching valve was found functioning properly but wanted to test it again in the morning when it's cold. The gave me a loner to get around for now. Will the 3rd time be a charm???

Justme · #26 (**permalink**) 05-06-2006, 02:14 AM

You are not alone.

My came back on this past Tuesday. I was really bummed. Took it to the dealer. They stated exactly the same thing, the switching valve was working fine. They kept it over night and gave me a loner but around noon the next day called and said it still is functioning normal.

Got on the horn with JBA. Talked to Dustin (ext 109 should want to call) and he said that I was the fourth one to have this problem. He did not give me a song and dance about it beings Toyota's fault and said he knew nothing about a recall. He did say that replacing the header may solve the problem, at least it did with one other that had this issue. He said he would get one set out that day and should be here today. So.... it did come and I have already replaced the old one with this new one. Ran into a small problem in that I could only find one dealer in town that had a exhaust gasket. Ran 20 miles up there to get it. Turns it, it was for the passinger side which I didn't realize until I already had the old header off.

In a bind, I called Mustang67408 and told him my problem. He said that using the old gasket should be fine since I only had used it for about a week. I certainly do appreciate him taking the time to chat with me about this.

Now the wait begins. BTW, while the truck was in the shop, the regional service manager was in town and they asked him about this. He said he had never heard of it. In talking with the local service manager, he and I discussed the issue at length. He believes the headers may be TOO efficient?!?! He said the basic issue is the sensor is not feeling the back pressure. His theory is the JBA headers may work so well that the back pressure is reduced with causes the error. Possible, I suppose.

I applaud JBA for standing up and admitting there may be an issue but I was not pleased to learn at first they wanted me to pay the shipping both ways for the replacement. I got on the horn with Autoanything whom I purchased these through and then JBA called back and said they would cover the shipping. I was also not pleased when I found out they actually charged my credit card for the header saying they would issue a credit when the old one came back. It was my understanding that they only wanted my cc number to put a hold on it and was very disappointed to see it appear online as a actually charge.

Quick question if anyone knows (Victor?) When I got the truck back from the dealer, they had reset the computer so the light was not on. I understand it needs to cycle a few times before it will trigger the light. Since I have replaced the header before it came on, should I reset it again to clear any pending codes or if this new header does fix the issue, will it clear itself? Thanks!

Justme · #27 (**permalink**) 05-06-2006, 02:14 AM

You are not alone.

Mine came back on this past Tuesday. I was really bummed. Took it to the dealer. They stated exactly the same thing, the switching valve was working fine. They kept it over night and gave me a loner but around noon the next day called and said it still is functioning normally.

Got on the horn with JBA. Talked to Dustin (ext 122 should want to call) and he said that I was the fourth one to have this problem. He did not give me a song and dance about it beings Toyota's fault and said he knew nothing about a recall. He did say that replacing the header may solve the problem, at least it did with one other that had this issue. He said he would get one set out that day and should be here today. So.... it did come and I have already replaced the old one with this new one. Ran into a small problem in that I could only find one dealer in town that had a exhaust gasket. Ran 20 miles up there to get it. Turns it, it was for the passinger side which I didn't realize until I already had the old header off.

In a bind, I called Mustang67408 and told him my problem. He said that using the old gasket should be fine since I only had used it for about a week. I certainly do appreciate him taking the time to chat with me about this.

Now the wait begins. BTW, while the truck was in the shop, the regional service manager was in town and they asked him about this. He said he had never heard of it. In talking with the local service manager, he and I discussed the issue at length. He believes the headers may be TOO efficient?!?! He said the basic issue is the sensor is not feeling the back pressure. His theory is the JBA headers may work so well that the back pressure is reduced with causes the error. Possible, I suppose.

I applaud JBA for standing up and admitting there may be an issue but I was not pleased to learn at first they wanted me to pay the shipping both ways for the replacement. I got on the horn with Autoanything whom I purchased these through and then JBA called back and said they would cover the shipping. I was also not pleased when I found out they actually charged my credit card for the header saying they would issue a credit when the old one came back. It was my understanding that they only wanted my cc number to put a hold on it and was very disappointed to see it appear online as a actual charge.

Quick question if anyone knows (Victor?) When I got the truck back from the dealer, they had reset the computer so the light was not on. I understand it needs to cycle a few times before it will trigger the light. Since I have replaced the header before it came on, should I reset it again to clear any pending codes or if this new header does fix the issue, will it clear itself? Thanks!

05Limited · #28 (**permalink**) 05-06-2006, 09:26 PM

Hopefully the new headers will solve your problem... If that works, I'll try the same route. If not, I might try putting the stock muffler back on and see if anything changes. I'd rather not have to go through the header install again.

It seems to me that higher velocities in the header would create more vaccum for the sensor to pick it up. I'm so puzzled. Can anyone post more details around the sensor that's suppose to pick up exhaust pulsations and how it senses it? Maybe there isn't pulsations anymore with the JBA headers.

Dealer called me back and said they were going to order a new switching valve again. The tech said the valve appeared to be stuck closed this morning and threw a pending code. If I remember right, it's 2 trips before the CEL goes on or off. I have had the light go off before when it was warmer or driving several trips in one day.

Anyways, I'm suppose to get the truck back on Tues\Wed. I miss the truck but can't complain about mpg improvement driving the camery around.

Justme · #29 (**permalink**) 05-08-2006, 03:38 AM

CEL came back on.

I am so disgusted with this whole ordeal. The down town, the running around to dealers either for parts or repairs and I'm right where I started. And to think the only solution (if you can call it that) is to put on the stock exhaust manifold. Disregarding the cost of the headers, the cost of all this running around, the three sets of nuts, manifold and collector gaskets is wearing me down. And will I get a refund of the header purchase if it comes to that??? To say the least, I'm not a happy camper.

Going to give JBA another call and see what they want to do. I just wish someone could figure out what the real source of this problem is. It is hard for me to understand how the headers could be 'source'. When you really try and understand the problem, how could the JBA headers be hiding the back pressure? Could it be just the opposite, ie, allowing to much back pressure which causes the switching value to malfunction? And why is it always the drivers side, no one has ever mentioned the passinger side (P2440, correct?)? If JBA has sold 100's of these, why is the problem only surfacing in so very few cases and continues to be a problem after repeated replacement of the switching valve?

On a different note, if I were to take my truck to a different dealer to look at this problem, would they pull up my previous repair history from the other dealer and elect to not do anything or would they treat it as a first time issue? Just curious. Thanks.

05Limited · #30 (**permalink**) 05-11-2006, 12:47 AM

Justme, I think I called JBA right after you did today. I hope you are making some progress. I hope your 3rd set is better will be the ticket

.

I finally got the truck back today and the tech guy said that the valve is sticking closed because the sensor is not picking up the pulsations/backpressure. The headers are either "too" free flowing or there is a blockage or restriction in the air tube. The next step for them was to return to stock manifold or tap the header to confirm no back pressure. Of course, I declined for them to do that cause it would have now been out of my pocket and not under warranty. Thank god they didn't try to back bill me for all the work.

I called Dustin and we are going to try a new set of headers. I'll ask them to at least bench flow test it to make sure there's no restriction in the air tube. I picked up a new set of lock nuts and ordered new air tube gaskets. BTW how much were the OEM exhaust header gaskets? I was shocked at it was about $100 for a set. The parts guy thought it was odd too for it to be that costly. So, I'll ask JBA to send me a new set with the return.