Codes P2440 and P2442 Air Injection System Fault Solution with pictures - ClubLexus - Lexus Forum Discussion


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Codes P2440 and P2442 Air Injection System Fault Solution with pictures

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Old 01-03-16, 02:45 PM   #1
bigphil001
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Default Codes P2440 and P2442 Air Injection System Fault Solution with pictures

I have a 2010 GX460 with about 81000 miles on it. I recently got the above codes and after researching it I decided to take apart the air injection valves, and also the motor to see what was going on.

Luckily these parts are very easy to access on our cars. Take the engine cover and front plastic cover off. The two valve are on either side of the cylinder head, and the pump will be on the left hand side, front of the engine bay.

I ordered two new valves, and ended up just cleaning out my pump.

Here are the Part Numbers and cost:

VALVE ASSEMBLY, AIR SWITCHING
2570138100
Quantity:1
Price:$192.95
VALVE ASSEMBLY, AIR SWITCHING
2570238050
Quantity:1
Price:$244.15

This is exactly what happened:

http://carspecmn.com/gx460-check-eng...5-andor-p0418/

Here is what both of my valves looked like:







Here is what the air pump looked like:











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Old 01-03-16, 03:54 PM   #2
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Why didn't you post this in the recently updated thread? Thanks for the info.
https://www.clublexus.com/forums/gx-...take-pump.html
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Old 01-03-16, 08:22 PM   #3
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another filter sucked in the pump. there is actually a tsb i found on the subject while diagnosing my own codes. it specifically talks about the filter getting sucked into the system. i hope everyone takes note of this. i got off easy with a $15 fuse and cleaning out my pump. i never took my valves apart so i dont know what all got sucked in there. i will cross that bridge if it comes up. mine was a 2010 with 78k on the odd. i do not have a filter anymore eta: there sure looks to be a lot of moisture in your pictures.

Last edited by machine323; 01-04-16 at 02:39 PM.
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Old 01-04-16, 10:42 AM   #4
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Thanks for the details. The linked article indicates that Toyota redesigned these parts, but doesn't say when or for what application. Did you notice that your new parts had a different design? Foam filter deleted? Or maybe there's a new design at 2014 and up?

Edit: I went ahead and posted the question on the article as well.
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Old 01-05-16, 11:43 AM   #5
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Quote:
Originally Posted by Jacket View Post
Thanks for the details. The linked article indicates that Toyota redesigned these parts, but doesn't say when or for what application. Did you notice that your new parts had a different design? Foam filter deleted? Or maybe there's a new design at 2014 and up?

Edit: I went ahead and posted the question on the article as well.
I ended up cleaning out the pump and am currently running it with no filter on it.

The valves look to be exactly the same though.

I don't think its a big deal to run without a filter since this pump only runs for a short time after a cold start and the air only gets dumped into the catalytic converter.
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Old 01-11-16, 02:05 PM   #6
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bigphil, or anyone. do you have pics of what a new valve is supposed to look like. seems like that is part of my problem also now. guess some stuff was still in the valve from when the filter god jacked up and is now rearing its head
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Old 01-11-16, 02:10 PM   #7
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Not my air valve but this is about what it should look like

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Old 01-11-16, 02:44 PM   #8
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did you just change the tops or the whole valves. the rubber that seems to be all melted in the pic does not look like foam stuff. something more like a gasket or something.
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Old 01-11-16, 02:51 PM   #9
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When you buy the valves from Lexus if you unscrew the 4 torx screws on the valve it will break into 3 pieces

First piece:


Second piece is this orange seal piece that is circled in my picture. I took a flat head screwdriver to mine and they popped right out


The third piece is the cast aluminum piece that is bolted to the engine and then exhaust tubes.

When I replace mine I left the cast piece bolted to the engine and tubes and only replaced the black valve portion and the rubber seal/valve piece that fits into the aluminum piece.

I'm not sure why mine looked like that but from searching on the internet thats what most of them have looked like.
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Old 01-29-16, 10:06 AM   #10
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Default TSB p2442

I'm glad to see this fault code discussed here! My 2010 GX just threw the code and Lexus Dallas gave me a $2600 quote to fix (secondary air injection system switching valve stuck open on bank #2). this seems quite high after referencing the photos on the post below. I am fairly skilled at repair issues but so far only on Old classic cars. In anyone's opinion is this something I can dig into and successfully fix?!! I have yet to see the car in person to reference these components. Of course this is my wife's daily driver so down time gotta be kept at a minimum!! Thank you for any feedback and direction !
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Old 01-29-16, 10:34 AM   #11
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Quote:
Originally Posted by Louis3 View Post
I'm glad to see this fault code discussed here! My 2010 GX just threw the code and Lexus Dallas gave me a $2600 quote to fix (secondary air injection system switching valve stuck open on bank #2). this seems quite high after referencing the photos on the post below. I am fairly skilled at repair issues but so far only on Old classic cars. In anyone's opinion is this something I can dig into and successfully fix?!! I have yet to see the car in person to reference these components. Of course this is my wife's daily driver so down time gotta be kept at a minimum!! Thank you for any feedback and direction !

IMO this is an extremely easy fix, the components are easy to find and replace. Lexus moved them out of the V in the engine like the Tundra engines so they are very easy to access.

Do yourself a favor and order the two replacement valves. I ended up not replacing the aluminum piece, only the valve's themselves (the replacement valves will come with the aluminum pieces).

I've been code free for about 3000 miles and countless freezing cold starts.
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Old 01-29-16, 10:51 AM   #12
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Additionally ... Can anyone recommend the best Lexus or secondary parts supplier for the air pump and valves? Lexus quoted me $900 for pump and $300/400 for each valve! Hopefully I could salvage the pump.
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Old 01-29-16, 10:57 AM   #13
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Quote:
Originally Posted by Louis3 View Post
Additionally ... Can anyone recommend the best Lexus or secondary parts supplier for the air pump and valves? Lexus quoted me $900 for pump and $300/400 for each valve! Hopefully I could salvage the pump.
http://www.lexussouthatlantaparts.com/

$440 for both valves

2570138100 VALVE ASSEMBLY, AIR SWITCHING 1 $192.95
2570238050 VALVE ASSEMBLY, AIR SWITCHING 1 $244.15
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Old 01-29-16, 11:07 AM   #14
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Thanks BigPhil!! I'll try and salvage / clean the air pump and simply replace the 2 valve assemblies. Guess I gotta move quickly on this. Louis
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Old 01-31-16, 10:50 AM   #15
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I got my valves from Toyota part.com for $466 shipped 2 day air. I cleaned up my pump and salvaged it. check the other thread for a replacement filter I used. I also had a blown fuse from the air pump that cost $13. I did change out the entire valve assembly though, just not the tops. took me 4 hours to remove and replace the. they are some tight places for the bolts if you want to change the entire assembly. better have a good assortment of different size 10 and 12MM sockets and ratcheting wrenches. don't use 12 point either. bolts seem soft to me and was wanting to round things off and I was using snap-on tools.
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