New Tundra Air Injection System Bypass Module Available

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A new solution is available for Toyota Tundras and Sequoias that have malfunctioning air injection system. Tundra Headquarters first ran an article “Tundra and Sequoia $4000 Air Injection System Problem” in 2010 when the stories of outlandish repair costs to the nonessential system began flooding forums and blogs. While Toyota has since warrantied the air injection system on 2nd generation (2007 and up) Tundras and Sequoias, this warranty isn’t perfect:

  1. There is no warranty for 1st generation Tundras or Sequoias that have this problem
  2. The warranty ends after 10 years or 150k miles

However, a custom module being offered by a TundraSolutions.com member promises to “fix” your air injection system for less than $100.

Air Injection System Bypass Module

This custom module tricks your Tundra or Sequoia into thinking that the air injection system is functioning properly.

What Is The Air Injection System?

There are two answers to this question. Some would say that the real problem is the very existence of the air injection system. Others would say it’s a Toyota quality and design issue.

First, understand that the Tundra’s air injection system is part of the federally mandated emissions requirements. The system improves cold-start emissions by pumping fresh air from underneath the front wheel well into the air intake. This additional pumped-in air goes through a set of valves that open directly into the exhaust system. Immediately after vehicle start-up, this freshly pumped air helps the catalytic converter heat up more quickly, which in turn makes the cat more effective at scrubbing exhaust gases.

Typically, the air injection system runs for 1-2 minutes during a “cold” start up, which is to say that there are many times in the warmer months where the air injection system isn’t activated.

Finally, understand that the air injection system is not essential – it’s simply a system Toyota has come up with to comply with EPA cold start emissions regulations. If this system was not required by law, your vehicle would cost less, run better, and be more reliable.

What Causes The System to Fail?

Air injection system problems are defined by three key issues.

  1. Condensation can build up inside the air pump and/or pump tubing, and over time this condensation can caused the air injection pump to fail. Once a pump fails (there are two), a check engine code will be set.
  2. Often times, when a pump fails due to moisture, the system’s switching valves have rust issues as the pump has been sending water into the valve. Even if the pump is operation, the switching valves can rust shut, which will also set a check engine code.
  3. Even though the air injection system is non-essential, it’s failure can trigger the engine computer to force the vehicle into limp mode. Once your Tundra is in limp mode, you’ll see flashing lights on the dash and have very little power. Not every system problem causes your truck to go into limp mode, however. Some Tundra owners are able to ignore their check engine light…at least until they must pass an emissions test.
Once the air injection system fails, your options are pretty limited. If you’re not covered by warranty, you can:
  1. Purchase a code scanner and clear the codes yourself. Scanners cost around $100, and then to clear the codes you’re looking at a 10-15 minutes process each time you plug in (Toyota puts a 10 minute delay on scanning capabilities as a theft deterrent). Even still, clearing codes isn’t a , there is no guarantee that you won’t face the same code next time you try to start your truck.
  2. Attempt a DIY repair. The parts for this fix are relatively inexpensive, so if you’re good with a wrench you can save a lot.
  3. Purchase an Air Injection Pump Bypass Module, as described below.

What is the Air Injection Pump Bypass Module?

A crafty Toyota driver has engineered an air injection pump bypass module that tricks the truck’s computer thinking the pumps and valves are working.

The module itself is wired into the mass air flow (MAF) sensor harness, and it gives your Tundra’s engine computer the impression that the air injection system isn’t needed. Instead of the computer trying to turn on your truck’s non-functioning air pumps and/or open the switching values (which will cause the check engine light to come on), the truck just does a normal start-up.

The cost of this little miracle? Only $75.

After install. the Air Injection System Bypass Module is nearly undetecable

When should you use the air injection pump bypass module?

If you have engine codes P1441, P1442, P1444, P1445, P2440, P2441, P2444 or p2445 and your vehicle is not covered under warranty, this module was designed with you in mind. However, bare in mind that this module isn’t a “factory” fix and it’s not technically legal either. While unlikely, any after-market part can cause problems if it isn’t designed or installed properly.

Speaking of the law, the risk here to the people buying this module seems very very small. While air injection systems are federally mandated, the only way to know that the bypass module has been installed would be to visually inspect the air injection system…and even then your inspector would have to know what he/she is looking for.

Bottom Line: If your Tundra or Sequoia is suffering from a malfunctioning air injection system and you’re not covered by warranty, you can order a bypass module by visiting this thread on the Tundra Solutions forum. Since this module is handmade, there can be several weeks between order time and receipt. Check it out.

P.S. Big thanks to the creator of this module, who will no doubt save dozens or hundreds of Tundra owners thousands of dollars in emissions system repairs!

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  • 2012 tundra 5 7 AIP bypass kit
  • 2011 tundra secondary air pump delete
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  1. […] Re: Air Induction Pump Bypass Module – AIP Valve Bypass Hey pxsp!! Free advertising!! New Tundra Air Injection System Bypass Module | Tundra Headquarters Blog […]

    • Paul (PXSP) says:

      Just wanted to post an update since this article is almost 2 years old but still getting a lot of views. “The Original Bypass Module” mentioned in this article is still available as a kit and I always have plenty in stock and ready to ship. Pricing in the article above was for the bypass module only.

      The kit includes the module, block off plates and 10′ of starter relay wire. Free Priority Mail Shipping and a Lifetime Limited Replacement Warranty!

      Kits are now available for the following Toyota and Lexus vehicles:
      Tundra: 2005-2009 4.7L,
      2010-2014 4.6L,
      2007-2014 5.7L,
      2007-2010 4.0L
      4Runners: 2005-2009 4.7L,
      2010-2011 2.7L
      Tacoma: 2005-2014 2.7L,
      2012-2014 4.0L
      Land Cruiser 2007 4.6L,
      2008-2014 5.7L
      GX460/470 2005-2009 4.7L,
      2010-2014 4.0L
      LX470/570 2006-2007 4.7L,
      2008-2014 5.7L

      You can contact me at paul@hewitt-tech.com with any questions and for the most up to date ordering information.

      • Alan says:

        Could you send me the info on pricing and where to purchase kit with blocking plates please? 2005 sequoia 4.7 with codes p1442,p1445,p2441 Thank you, Alan

  2. LJC says:

    There are two problems, the obvious one is the pumps failing prematurely.
    The second, which is worse, is the Tundra going into limp mode.
    What’s not entirely clear is if the pumps fail, does it create a dangerous condition?
    If it doesn’t, then there is no need for the Tundra going into limp mode, which in itself can create a dangerous conditon.
    Here are two more thoughts:
    1) A failed O2 sensor does worse for the environment than a failed or “missing” air injection pump.
    2) I believe it’s proven that synthetic oil benefits the environment, I think the syn. oil benefits alone can exceed those of the injection pump.

    In summary, the air injection pumps are creating way more problems than they are solving, so this module sure looks like a great solution.

    • LJC – I agree. If the damn ECU didn’t go into limp mode, fixing these pumps would never be necessary. It’s a big rip-off if you ask me…the EPA mandates this convoluted system, then the auto manufacturers half-ass it, and the vehicle owners foot the bill.

      I’m all for making the Earth a clean and beautiful place. However, emissions regs should pass the common sense test. Better to skip this system and mandate everyone recycles their motor oil or something…

  3. LJC says:

    Hold on man, I thought the Land Cruiser used the same engine are the Tundra? If it does, does the LC suffer from the same problem?

    • If it does, your typical LC owner isn’t complaining very loudly. My guess? If you can swing $75k for a new vehicle, you probably don’t squelch too loudly when the shop asks for a $4k repair.

    • Paul (pxsp) says:

      Yes the Land Cruiser uses the same engine, however, I believe they are still assembled in Japan. I think the majority of the problem lies in the state side assembly ad sourcing of domestic parts used in the more popular Tundras.

  4. mendonsy says:

    “Limp Mode” only occurs when a “valve stuck” CEL is generated (P244x). A valve failure can create a condition which can damage the hoses between the pumps and valves. In order to completely disable the AIP system you have to install this mod plus valve blockoff plates on the exhaust manifolds.
    If the valves are working properly when the mod is installed they should be OK because they stop operating, but there is no guarantee of that.

  5. 10platcrew says:

    The way I understand it, the air injection system is to help with cold engine emissions. How come we have them and nobody else does? Ford, Chevy, Dodge, even Nissan do not have air injection systems on any of their gas light duty truck engines. Even with this system, the Tundra has the highest Co2 output. http://www.fueleconomy.gov/feg.....8;id=31451

  6. Paul (pxsp) says:

    I am glad to see the word is getting out! Thank you for the blog write up. Please refer to the most up to date forum thread for accurate information about the modules or to order: http://www.tundrasolutions.com.....ost1834940
    As mendonsy mentioned block off plates should be used. I am looking into having block off plates manufactured out of stainless steel to complement the module.
    Thanks,
    Paul (pxsp)
    Module Designer

    • Paul,

      No, thank you for creating this module. You are saving people lots of dough!

      -Tim

      • Paul (pxsp) says:

        In that case, lol… Anyone is welcome to share their repair savings with me. I make very little profit on these modules and can use all the help I can get to finish paying for my Electrical Engineering degree.

  7. Mickey says:

    Agree Tim… Paul has helped alot of people with that mod. Unfortunately I haven’t had the need for it. Also just under 145k miles doesn’t leave me much time/distance left for warranty.

  8. Paul (pxsp) says:

    Updated Link as the one in the article is broken.
    http://www.tundrasolutions.com.....odule-aip/

  9. Sorin says:

    Hello

    How can I order the module? I’m from Canada

  10. Ronny says:

    Paul (pxsp),

    Awesome info. Do you still have any module kits available?

    Thanks,

    Ron

    • Paul (pxsp) says:

      Yes, Modules are available. Canadian Orders add $15 for Priority International 10-15days or $30 for International Express 5-10days.

      • Jill says:

        Paul – Are there any reviews written on these modules? I’ve been handed a 4k bill that I cannot pay and still owe 10k on my Sequoia.

        • Paul (pxsp) says:

          Hey Jill,
          I have had only have a few people leave comments on the forum thread and many more have expressed their satisfaction with the quality of the module, packaging, installation instructions and the block off plates via email. Everyone has been very satisfied and I will try to keep it that way by doing whatever I can to help the customer.

  11. Abdul Tambey says:

    I have a question on this article: Warranty on the 2007 2nd generation is changed to 150K but my dealer is saying no warranty. Even though I also have the life time power train…at 73K miles on my Sequoia, I am not covered.

    While Toyota has since warrantied the air injection system on 2nd generation (2007 and up) Tundras and Sequoias, this warranty isn’t perfect:

    There is no warranty for 1st generation Tundras or Sequoias that have this problem
    The warranty ends after 10 years or 150k miles

  12. […] another super complex system to break. Looks like some of the tundra folks are removing theirs. New Tundra Air Injection System Bypass Module | Tundra Headquarters Blog That's tempting. __________________ .:*~*:._.:*~*:._.:*~*:._.:*~*:._.:*~*:._.:*~*:. OLD 2007 […]

  13. […] Worst case you can bypass it like the Tundra guys. Link from the thread in the General Section. New Tundra Air Injection System Bypass Module | Tundra Headquarters Blog Haven't seen one of these in person and hopefully Toyota fixes it for you. Good luck and post […]

  14. D says:

    Would this clear the check engine light and allow the truck to pass emission testings?

  15. michael harrell says:

    Hi.
    I’ve been dealing with this issue on my 2005 sequoia for about 3 years. Actually had it serviced at the dealership once using remanufactured parts to save some money. The problem returned in less than a year. I read above that there is a custom module being offered by a TundraSolutions.com member promises to “fix” the air injection system for less than $100. I’m not a TundraSolutions.com member but would like to know to get one of these modules (for as little $ out of pocket as possible.
    I hope someone replies…Thanks!

  16. Selby Goss says:

    Paul, I want to order one of your Air Injection Bypass modules, but not clear on how to order! My 2006 Sequoia has one of the valves stuck closed! P1445 code! The local Toyota dealer wants $3,300 plus tax to repair!

  17. Wayne says:

    Just replaced the Air Injection Pumps on my 2007 Tundra DC 4×4 5.7, thankfully under the 10 yr 150k warranty. Dealer told me that with water in the pumps I needed to replace the Air Injection Drivers as well. Does this make sense or did I just pad the dealer’s wallet?

    Thanks for the help.

  18. […] Re: 2013 Fj part You might try this… Let us know if you do, and if it works. New Tundra Air Injection System Bypass Module | Tundra Headquarters Blog […]

    • Anonymous says:

      The kit will be coming soon to the 1GREFE V6 in the Tundra, FJ, Tacoma etc.. Also the 2TRFe I4…

  19. DaveK says:

    If anyone is interested, we have a very simple, plug&play solution – NO cutting, NO soldering. Available direct from us (click on my name here), or on Ebay. Less than $200, comes with exhaust block-off plates.

    • DaveK says:

      Apologies for the website error in my post – best bet is to find these modules on Ebay – look for ‘Toyota AIP Bypass Kit’, and you’ll find a variety of options.

  20. Paul (PXSP) says:

    The modules mentioned above by DaveK are not affiliated with my kits and are not the subject of the the original article.

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