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Discussion Starter #1 (Edited)
Secondary Air Injection System Bypass Kits a Plug and play for 2005-2012 Toyota/Lexus Vehicles.

You can purchase your Original SAIS Bypass Kit Plug and Play or Wired Version directly from our website: http://hewitt-tech.com
We can now cover almost every SAIS code with kit addons check out the codes page of our site to see what you need or contact us.



Give us a Call Toll Free 1-844-307-7671
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Subscribe to our Youtube Channel: https://www.youtube.com/playlist?list=PLb0PURtYjcMSdzgNiUueo8q4Sbqko84tq

Our V36 kits are available in Plug and Play and wired kits for the 05-07 vehicles and our V52 kits for the 2008 - 2012 and newer vehicles are plug and play only!
The V52 kits are here: Hewitt Technologies Inc - V52 Kits


We also have shop kits and special pricing for dealers (ask for details) as well as pump repacement packs and OBDII Tools!



We now have a pump replacement pack that will let you clear a P0418 or P0419 code after installing the bypass kit. They are especially beneficial if you have a 4.7L where the air induction pump is located underneath the intake manifold. No need to buy an expensive air pump and since they install at the pump driver(s) there is no need to remove the intake manifold!



You can purchase your Original SAIS Bypass Kit Plug and Play or Wired Version directly from our website: http://hewitt-tech.com


You can now purchase directly from our website: http://hewitt-tech.com
Installation Instructions can now be directly downloaded from our Instructions Page




A failure of any component of the SAIS will generally set the check engine light (CEL) and cause the Engine Control Module (ECM)
to store trouble codes. Many of these mechanical failures will also cause the vehicle to enter “limp-mode” where throttle
response is limited to 50% to protect the engine from damage. Before installing the bypass module it is highly recommended to
address any codes not related to the SAIS. The codes below are the most common trouble codes that the bypass kit is able to let
you clear once the kit is installed and the codes are initially reset. Many of these codes can be caused by a failing SAIS Air Pump
which can also cause a loud vacuum cleaner noise for 20-30 seconds after a cold start. After the kit is installed the system is
prevented from operating and the below codes should not come back on, set the CEL or let the vehicle enter into “Limp Mode”
In general, the SAIS Bypass Kit cannot clear codes that are related to electrical faults or circuit malfunctions with the exceptions
of a few below and only under certain circumstances with the addition of a Pump Replacement Pack or a Pressure Sensor Jumper Harness to the bypass kit.



"Standard" codes the kits can usually take care of by themselves

P1441 - Switching Valve No.2 Stuck Open Bank 1
P1442 - Switching Valve No.2 Stuck Close Bank 1
P1444 - Switching Valve No.2 Stuck Open Bank 2
P1445 - Switching Valve No.2 Stuck Close Bank 2
P2440 - Switching Valve Stuck Open Bank 1
P2441 - Switching Valve Stuck Closed Bank 1
P2442 - Switching Valve Stuck Open Bank 2
P2443 - Switching Valve Stuck Closed Bank 2
P2445 - Pump Stuck OFF Bank 1* Important cold weather note
P2447 - Pump Stuck Off Bank 2
There is the occasional exception like a blown air pump fuse or damaged air pressure sensors.

Codes the kits can take care of with the addition of a Pressure Sensor Harness

P2431 - Air Flow / Pressure Sensor Circuit Range / Performance Bank1
P2432 - Air Flow / Pressure Sensor Circuit Low Bank 1
P2433 - Air Flow / Pressure Sensor Circuit High Bank 1
P2436 - Air Flow / Pressure Sensor Circuit Range / Performance Bank 2
P2437 - Air Flow / Pressure Sensor Circuit Low Bank 2
P2438 - Air Flow / Pressure Sensor Circuit High Bank 2
P106B - Pressure Sensor Correlation / Evap. Pressure Sensor
Only vehicles with two pressure sensors (one must be good) can take advantage of the Pressure Sensor Jumper Harness.
Codes the kits can take care of with the addition one or two Pump Replacement Packs

P0418 - Relay 'B' Circuit Malfunction
P0419 - Relay 'B' Circuit Malfunction
Usually caused by an open circuit/damaged air pump motor. One pack is needed for each code. Silver and Gold kits come with one.

Installing exhaust block off plates along with the bypass module is the only way to ensure the system is fully isolated and does not cause any future problems. The module can only prevent codes that are set because of leaking or stuck valves with block off plates installed. Sometimes valve trouble codes can be set by only a bad air pump but it is recommended that plates be installed if any codes for the valves are present. If you want to look at the installation instructions for more info or to get a better idea how to install the module and block off plates just send me an email and I will forward PDF copies for you.


Limited Lifetime Replacement Warranty and Expert Customer service and support!
Tried and Tested Unparalleled Reliability Designed In. Often Shipped Same Day.



How To Order:

1) If you have any questions about the bypass kit or your trouble codes please contact us through our website using the Contact Us page. You can also download the latest installation instructions from out Instructions page.
2)Go To http://hewitt-tech.com. Select your vehicle and the engine/year from the drop down menu and checkout with a card or paypal.


Module Specs:
Compact Solid State Electronic Module (no mechanical or moving parts)
4cm x 4cm x 1.3cm Black Duroplastic High Temp Enclosure
3M Automotive Double Sided Tape for mounting
Epoxy Potted for environmental protection
Simple 5 wire hookup at the MAF/IAT sensor (wire diagram and vehicle wire color included in instructions)
18" 20awg TXL wire leads for easy connection.
Illustrated installation instructions
For off-road or racing use only.
Assembled by hand in the USA!



DSC00054.jpg DSC00056.jpg 47L Plates.jpg 57L Plates.jpg 20130306_151704[1].jpg Instruction Picture.PNG
Just a few samples of my EBAY feedbacks, check out hundreds more here:Ebay Feedback
Excellent Item!!! Exceeds my expectations and is well worth every penny!!! Buyer: Member id rip662
Awesome product. So simple to install and it works wonderfully. Buyer: Member id gwds69
Worked PERFECT!! Easy install. Thanks a million. (Or $2000 - $3000 saved) Buyer: Member id speedjunkie99
Absolutely amazing, fault code gone and passed emmissions. It's a great fix! Buyer: Member id jmckelveyjr
Exactly As Described! Great Price! Fast Shipping! Thanks! Buyer: Member id carsivservice
Hey everyone i purchased a module from pxsp and it works perfectly. The of it was way better than replacing the pump and a whole bunch easier. It's been on my truck for over a week now and have had no problems. If you have this problem with your truck you should definitely consider buying one from him.
My module came yesterday and installed it today. Worked perfectly - no code, no pump sound at first start up after setting for 24 hours. Thanks.
I installed my module this morning. It was so friking easy to do. Can't get easier then that pxsp :) Thanks. I’ll let you guys know how it works in 1 or 2 weeks.
Over all, no surprises, and easy install.
I have put hundreds of miles on the truck and the CEL has stayed off. Saved $3100, plus I got a new scanner for future diagnosis . COULD NOT BE MORE PLEASED!!!!!

SAS Failure:

If you are not familiar with the Air Induction Pump Or Secondary Exhaust Valve problems on the Gen. 1a and Gen. 2 Tundras consider yourself lucky.
Although Toyota extended the warranty on the 2nd Gen tundras to cover replacement or repair of the system plenty of us have been shafted and stuck with only 2 options to remedy the problem: pay several thousand dollars to replace/repair the AIP secondary emission system or go to lengths to bypass and eliminate the system all together. The AIP system simply pumps air into the exhaust on startup to help get the catalytic converters up to operating temperature faster and thus improve emissions. It does not have any affect on performance unless the system fails. Two modes of failure are common. The air induction pump fails or the exhaust valves get stuck open or closed. I encountered a pump failure on my 05' Tundra DC XSP a couple of months ago, since it is not covered by warranty and the quote I received from my Toyota dealer was $3400 to replace the system I began working on an engineered solution to disable or bypass the system. Disconnecting the pump will disable the system but cause its own engine code. If your exhaust valves are stuck or leaking you will also need to install exhaust block off plates to prevent exhaust from flowing back into the system and causing "limp mode" even if the system is bypassed.
 

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Discussion Starter #2
Here are the installation pictures on my 05 Tundra XSP Double Cab. Detailed instructions will be included with the module.
DSC00003.jpg MAF/IAT Sensor on top of airbox
DSC00002.jpg Location to be installed.
DSC00013.jpg Disconnect sensor and harness clip.
DSC00016.jpg Split wire loom
DSC00017.jpg Remove wiring.
DSC00022.jpg Mount module (looks crooked but I assure you it is level) and mock up wiring.
DSC00028.jpg Soldering your connections is always the best and least bulky method.
DSC00033.jpg Make proper connections according to instructions or vehicle pinout.
DSC00034.jpg Verify operation, insulate connections, candy stripe wires, close loom.
DSC00042.jpg Clean up harness to look like a factory install.
DSC00043.jpg Finished.
DSC00044.jpg Clean install...
Install block off plates, reset engine codes and start engine... AIP problem solved!
Typical install will probably take 1-2hrs including installing the starter relay wire and block off plates. The starter relay wire must also be connected to the starter relay by routing a 18-22AWG through the engine compartment to the bypass module.

Bypassing the system with the module will allow it to pass an emissions test. Most States will check the ODBII Monitors (emission system tests) for the vehicle. These monitors are are used to determine if all of the systems are operating properly. The bypassed Secondary Air System passes its monitor without any problems. The screenshot below is of the ODBII Monitors report for my 05 Tundra after a cold start-up (55 deg. F) and the bypass module installed. The Secondary Air System (Air Induction System) shows that it has completed and is functioning properly.
Monitor Report.jpg
Once the drive cycle to test the EGR and 02 Sensor Heater are completed the truck should be ready for emissions test. As long as you have no other problems than a faulty AIP system the vehicle should pass an emissions test.

Emissions:
Emission standards are different for each state so please consult your state laws. Most states will not pass your vehicle if there is a check engine light, if your SAS iscausing a CEL or your vehicle is in "limp mode" you will not pass emissions.
Because it is against federal law to disable any vehicle emissions control systems or to cause to be inoperable these modules are sold for off-road use only.
The Customer shall hold harmless the Seller for any claim of damages, loss, injury, cost, expense or legal complications that may arise from the purchase, use and or installation of the SAS Bypass Module
 

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Discussion Starter #4
Cross Posted from the old thread.

So with this module can we take the AIP crap completely off the truck?
The short answer is not really.

The bypass module only prevents the operation of the system and thus any codes that are generated from its faulty operation. Disconnection of the pump will prevent the system from operating but it will also cause its own fault code. Theoretically speaking, if you still want to completely remove the system you would have to replace the pump, vacuum valves and exhaust valves with equivalent power resistors to trick the computer into thinking that they are still connected. You still have to have the bypass module to do this because of the way the system checks for proper operation using pressure sensors.

Because getting at the valves and pump involve removing the intake manifold I do not recommend removing them at all. What I would suggest is simply removing the air tubes that connect the exhaust valves to the exhaust manifold and using block off plates to prevent any problems that may arise from the valves being stuck open. By using the block off plates and bypass module you will have effectively removed the entire system and problems caused by its operation or lack thereof.
 

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While it is true you can buy an old GM AIP from a junk yard for $25 and maybe make it work; that is not the focus of this thread. If you have replaced your Toyota AIP with a GM sourced part I would love to read about it in another thread. To me installing a $25 cash for clunkers part is asking for more trouble than just bypassing and eliminating the system. Remember, the AIP is not the only problem people are having with this system.
 

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I've spent the last several days looking into the repair/replace option and the best i can tell the repair is in the neighborhood of $2000.00 and up.* Labor is not too bad but the parts cost is a bit extreme, $1251.61 for Air Pump from the dealer.* I did notice people saying that a GM air pump will replace the Toyota's, but from what I've been able to find it's for the 07' and newer Tundras. Unless someone has a GM part# that will replace Toyota's part# 17600-0F010 this is looking like a very good option, so sign me up. PM sent
 

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I've spent the last several days looking into the repair/replace option and the best i can tell the repair is in the neighborhood of $2000.00 and up.* Labor is not too bad but the parts cost is a bit extreme, $1251.61 for Air Pump from the dealer.* I did notice people saying that a GM air pump will replace the Toyota's, but from what I've been able to find it's for the 07' and newer Tundras. Unless someone has a GM part# that will replace Toyota's part# 17600-0F010 this is looking like a very good option, so sign me up. PM sent
Here are the last three pages from the AIP Bypass pdf. It has part numbers. You most likely will not find a direct, 100% plug-in replacement because you can expect the connector to be different, and the connector from your old pump will need to be spliced on. Other than the connector, the pumps are identical.

Steve
 

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Hi guys,
I just bought a 06 and was thinking about buying some headers when I noticed the price difference between the 00-04 and 05-06 headers and then I noticed the air injection. Then I ran across StevJ's mod. Now I was thinking if I disable the AIP is there any reason I couldn't run the older headers without the plumbing?
 

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I had this problem with my 05 TRD AC almost two years ago. My truck sounded like a friggin' vacuum cleaner when it started cold. Then the pump quit working completely and threw my truck into limp mode. I think it's stupid that this part costs as much as it does, and that it throws the vehicle into limp mode. It only runs for about 30 seconds max, so why the need for limp mode? I quickly got used to letting the engine warm up, turning it off, and disconnecting the negative battery terminal to reset the ECU every morning before school. Anyway, my dad and I ended up complaining to Toyota USA corporate and they paid for the part and half the labor. We got away paying a little over $800. Still sucks.

If this had been available then, I sure would have purchased one.

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Then the pump quit working complete and threw my truck into limp mode. I think it's stupid that this part costs as much as it does, and that it throws the vehicle into limp mode. It only runs for about 30 seconds max, so why the need for limp mode?
Actually a pump failure will not cause limp mode but it will cause a CEL. What causes limp mode is a "valve stuck open" failure.
The reasoning behind limp mode is that hot exhaust gasses can get past a stuck open valve into the rubber tubing that leads to the pump which will cause damage to the hose and pump and possibly an engine compartment fire.
 

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I agree and just to make sure you are not leaking exhaust back through the system you should block off the exhaust ports on the manifolds. So if I am making the bypass module who is machining block off plates? I would trade a module for a nice machined set of stainless block off plates with exhaust gaskets and hardware.
 

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I agree and just to make sure you are not leaking exhaust back through the system you should block off the exhaust ports on the manifolds. So if I am making the bypass module who is machining block off plates? I would trade a module for a nice machined set of stainless block off plates with exhaust gaskets and hardware.
In Mendonsy's and in my sig you'll find links to the blockoff plate drawings and measurements. I think most folks are just whittling them out of a small sheet of stainless.

See the pic for an example (my first failed attempt)
http://www.tundrasolutions.com/forums/attachments/tundra/63620d1309818280-aip-simulation-circuit-1-blockoff-plates.jpg

Steve
 

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Actually a pump failure will not cause limp mode but it will cause a CEL. What causes limp mode is a "valve stuck open" failure.
The reasoning behind limp mode is that hot exhaust gasses can get past a stuck open valve into the rubber tubing that leads to the pump which will cause damage to the hose and pump and possibly an engine compartment fire.
How come my engine would come out of limp mode if I disconnected the negative battery terminal? I mean, if a valve was stuck open, wouldn't the CEL come back on after restarting the truck? Does it only get stuck open when it starts cold?

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How come my engine would come out of limp mode if I disconnected the negative battery terminal? I mean, if a valve was stuck open, wouldn't the CEL come back on after restarting the truck? Does it only get stuck open when it starts cold?

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The test that detects the "valve stuck open" is part of the AIP operation cycle. That test is not run when the coolant temp is above 104 degrees so it will not trigger on a warm start.
 

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The test that detects the "valve stuck open" is part of the AIP operation cycle. That test is not run when the coolant temp is above 104 degrees so it will not trigger on a warm start.
So I could have started a fire in my engine bay by doing what I did? Yikes! :eek:

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So I could have started a fire in my engine bay by doing what I did? Yikes! :eek:
Probably not! :rolleyes:
The test will detect a valve with even a slight leak or one that doesn't close quickly. The valve would need to be really bad to allow enough exhaust through the pump hose to do any serious damage.
 

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What is the difference between this module and StevJ's AIP bypass other then, "The module greatly simplifies bypassing of the AIP system and allows for a much cleaner installation. "
 
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