Hewitt-Tech Gen 1: Secondary Air Injection System Bypass Kit (Plug & Play) (2022)

Description

DESCRIPTION:
Hewitt Tech Generation 1 Secondary Air Injection System Bypass Kit (Plug & Play)
The Hewitt Tech (HT) Gen 1 Bypass Kit prevents operation of the SAIS at cold soak start. The Gen 1 is our basic bypass kit that enables you to clear the Check Engine Light, Limp Mode and error codes related to mechanical SAIS faults. The V54H is compatible with most Toyota and Lexus vehicles model years ’08 – ’12 and select ’13 vehicles. However, it is not compatible with Flex Fuel vehicles. Like the V36H, the V54H Plug & Play Gen 1 Bypass kit decreases labor/Install time with connectors compatible with the vehicle’s factory components. All wiring connections, except the starter relay wire, are achieved using the Plug & Play harness. It is made with automotive grade materials and designed to blend in with the factory wiring harness. This allows for a very clean factory looking installation. Easy to follow step by step installation instructions are included with vehicle specific illustrations. We recommend the Gen 1 Plug & Play Bypass kit for both professionals and DIY mechanics because of the ease of install and affordability. However, if the vehicles ECM has been flashed with an updated calibration file the Gen 1 may not be compatible. If the vehicle has been reflashed then you will need to purchase the Gen 2 Bypass Kit. Please see note below of for additional information*.

The following are Mechanical Trouble codes the Gen 1 Bypass Kit typically addresses**:

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***
P2447 – Pump Stuck Off Bank 2

The following are Trouble codes NOT addressed by the Gen 1 Bypass. These will require kit addon(s) in order to clear. However, if you are getting any electrical codes our recommended solution is the Gen 2 Bypass kit.

Electrical Codes

(Video) Toyota Lexus V35H Plug and Play Secondary Air Injection Bypass Kit Install - Hewitt Tech

P0412 – SAIS Switching Valve ‘A’ Circuit Malfunction Bank 1
P0415 – SAIS Switching Valve ‘B’ Circuit Malfunction Bank 2
P0418 – SAIS Circuit/Relay ‘A’ Circuit Malfunction Bank 1
P0419 – SAIS Circuit/Relay ‘B’ Circuit Malfunction Bank 2

Electrical SAIS error codes are usually caused by an open or short circuit in one of the Air Switching Valves or Air Pumps. Each code would require a separate addon.

Pressure Sensor Codes

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

These codes typically indicate a damaged Pressure Sensor which is usually caused by an Air Switching Valve being stuck open for an extended period of time. Functioning Pressure Sensors are needed for both Gen 1 and Gen 2 Bypass kits. Compatible Pressure Sensor addon required in order to clear.

(Video) Toyota Lexus Secondary Air Injection Bypass Kit - Wired vs Plug & Play Comparison - Hewitt Tech

GEN 1 Plug & Play BYPASS KIT INCLUDES:

  • 1 x SAIS Bypass Module – Plug & Play Connections (IAT & ECT)
  • 2 x Secondary Exhaust Valve Block Off Plates (Engine Specific)
  • 1 x 10′ Piece of Violet 20 AWG TXL – Starter Relay Connection Wire
  • 1 x Printed Copy – Detailed Bypass Module Installation Instructions
  • 1 x Printed Copy – Block Off Plate Instructions (Engine Specific)

FEATURES:

  • Bypass Wiring Harness:
    • Straight forward Plug & Play connections compatible with Factory components.
    • High Quality Automotive Engine Compartment Grade TXL Wiring
  • Bypass Module:
    • 4cm x 4cm x 1.4cm Black Duroplastic High Temp Enclosure – UL 94 V-0 Flame Resistance
    • Black Epoxy Potted for environmental and shock protection.
  • Block Off Plates:
    • 16 gauge (1/16 inch) 316 Stainless Steel Block Off Plate Construction for Lifetime Use
    • Water Jet Cut for Precision and Smoother Edges, Guaranteed to Fit Your Engine
  • Start Relay Wire:
    • ONLY available from Hewitt Technologies home of The Original SAIS Bypass Modules.
    • 10′ Piece of Violet 20 AWG TXL wire with female disconnect terminal.
  • 3M™ Automotive Acrylic Double-Sided Tape for mounting
  • Assembled 100% by hand in the USA!
  • Limited Life-Time Warranty

MORE ABOUT THE SAIS BYPASS KIT

What makes the Gen 1 (V54) Bypass Kit different than the Gen 1 (V36) Bypass Kit? In 2008 there was an update made to the computer programming that affected SAIS operations. With this change a new module had to be engineered with two harnesses; installing at both the Air Intake Temperature (IAT) sensor and the Engine Coolant Temperature (ECT) sensor. Our competitors have not taken this update into consideration with their products. That said, if you were install a competitor’s kit or Gen 1 (V36) on a model year ’08 or newer, you would get the error code P011B – Temperature Correlation Error. Just another reason to go with HT, the original SAIS bypass. Lastly, we have seen an intermittent chocking start issues on some vehicles using the Gen 1 (V54) ****.

The bypass module is activated when the ignition is first switched to “ON” and any time it detects a 4-12V signal on the starter relay wire. The starter relay wire is only available from Hewitt Technologies home of the Original SAIS Bypass Modules! When connected, ensures that the module actively prevents the SAIS from running on EVERY start.

(Video) How to install the Hewitt Technologies SAIS Gen. 1 bypass kit in a 2006 Toyota Tundra

With the starter relay wire connected you can turn the ignition to “ON” for any period of time and the module will be active as soon as you crank the engine. Without the starter relay wire connection, you would need to turn the ignition back “Off” and then crank the vehicle to ensure the module is active or the system could operate and cause trouble codes and the CEL to come back on. Just install the kit with the starter relay wire connection and don’t worry about having to start the engine as soon as you turn the key on! If anyone else drives the vehicle this is a Must!

The included Air Switching Valve Block-off Plates are an integral part of the bypass kit. The Block Off Plates are the only way to isolate the Air Switching Valves and protect the related Pressure Sensor(s) from damage caused by exhaust. Open Air Switching Valves and Pressure Sensors exposed to exhaust are the primary cause of Limp Mode and SAIS failure.

It is important to understand that installing a HT bypass will prevent your Air Pumps and Air Switching Valves from operating. However, it will not close the Air Switching Valves or keep them closed in the future. That said, choosing not to install the Block Off Plates leaves the SAIS vulnerable because exhaust may leak into open valves and damage the Pressure Sensors. As noted above, both Gen 1 & 2 HT bypass kits require kit addons to clear SIAS Pressure Sensor codes. Do yourself a favor, avoid future frustrations and costs; install the Block Off Plates.

If you are having a hard time determining which is the best solution for your vehicle, please do not hesitate to give us a call or send an email. Hewitt is here to help!

NOTE:

(Video) WATCH ME INSTALL HEWITT SECONDARY AIR INJECTION SYSTEM BYPASS KIT FOR 2006 GX 470

*Gen 1 Bypass Kits are not compatible with vehicles that have had the ECM updated with a calibration file from Toyota Technical Service Bulletin T-SB-0033-12. It is assumed that this ECM update will cause the secondary air system to operate at shutdown after the vehicle has reached operating temperature. Only Gen 2 Bypass can prevent SAIS system operating at shutdown. Click Here to Learn more.

**The vehicles fuses, Pressure Senor(s), factory wiring harness and Engine Control Module (ECM) must be in good working condition for bypass kit to operate properly.

***There is a known “Cold Weather Glitch” on some older 4.7L engines. If the vehicle is tripping a P2445 and it is caused by this glitch; the Hewitt Technologies SAIS Bypass Kit will not resolve the issues. Please visit our Error Codes page or give us a call to learn more.

****There is a known intermittent chocking start issue on vehicles that our more sensitive to after installing Gen 1 (V54) Bypass Kit. This is due to the tolerance in the engine temperature sensor. It most commonly occurs when the engine temperature is between 90 – 100 degrees.

+HT SAIS Bypass kits are engineered to work with Factory or OEM SAIS components. That said, aftermarket SAIS components can cause SAIS codes to be present after installation of the bypass kit. This typically means you will need a kit addon from Hewitt Tech in order to clear SAIS codes that are still present.

(Video) Gen-II Secondary Air Injection Bypass Module - 2007-2020 Tundra 5.7L- Hewitt Technologies

DISCLAIMER:

It is illegal to remove, dismantle or otherwise cause to be inoperative any pollution control device required by federal, state, or local emissions law. Our bypass kits are sold for off-road, competition or other emissions exempt vehicles only. No other applications are intended or implied. By installing or using this SAIS Bypass Kit the vehicle owner and installer acknowledge and assumes ALL risks associated with its use.

FAQs

How do you fix a secondary air injection system malfunction? ›

What repairs can fix the P0410 code?
  1. Replacing the air injection pump and power relay.
  2. Replacing O2 sensors that respond too slow as they age.
  3. Replacing the air injection pump intake filter clogged with debris.

Is secondary air injection necessary? ›

The air injection smog pump pushes air into the exhaust system right after the exhaust manifold, to help intercept and burn those unburned fuels. The system is critical to help cars achieve government emissions standards. So, the law says you need a secondary air injection system.

How do I fix error code P2445? ›

What repairs can fix the P2445 code?
  1. Replacing the secondary air injection pump.
  2. Repairing or replacing wiring or connectors that are associated with the air pump.
  3. Replacing the serpentine belt.
  4. Replacing a fuse.

What causes a secondary air injection pump to fail? ›

CAUSES OF A FAILURE: CAUSE OF FAILURE

Faulty ground and voltage supply can also cause the pump to fail. Blocked or leaking lines can also cause the failure or malfunction of the control or combination valve, resulting in the failure of the secondary air system.

What happens when secondary air pump fails? ›

What Happens When the Secondary Air Pump Fails? A secondary air pump failure will not be the end of the world, simply because it is not the main air intake. Of course, it can lead to power loss, idling issues, or stalling during cold starts. Pump failure will also affect the emissions output of your vehicle.

Can a secondary air pump cause a misfire? ›

Can a Secondary Air Pump Cause a Misfire? Yes, a misfire is a common sign of a faulty secondary air system. If the pump isn't working properly, there will be too much fuel and not enough oxygen in your vehicle, which often results in a misfire.

What happens when air injection fails? ›

If your secondary air injection pump has failed, you may notice that the catalytic converter is not working as well as it should. This problem can lead to a loss in power and performance from your engine. The catalytic converter is the engine's first line of defense against harmful emissions.

Does the secondary air pump run all the time? ›

During a cold start, the secondary air pump may only be in operation for a maximum of 90 – 120 seconds. The secondary air pump is not designed for continuous use!

What is the point of secondary air injection? ›

Secondary air injection (commonly known as air injection) is a vehicle emissions control strategy introduced in 1966, wherein fresh air is injected into the exhaust stream to allow for a fuller secondary combustion of exhaust gases.

How do I fix code P2440? ›

What repairs can fix the P2440 code?
  1. Replace faulty air injection valve.
  2. Replace faulty one-way check valve.
  3. Replace faulty air injection pump.
  4. Replace faulty pressure sensor.
  5. Repair or replace frayed, broken, or shorted pressure sensor wiring.
  6. Repair or replace damaged or corroded pressure sensor connector.

What is code P0418 mean? ›

What Does the P0418 Code Mean? Diagnostic trouble code (DTC) P0418 stands for “Secondary Air Injection System Control “A” Circuit.” The A designation can mean it's the only circuit or its specific circuit out of multiple circuits in the system.

What is code P2441? ›

The trouble code P2441 would mean that the PCM has actually detected a problem with the secondary bank in the air injection system, which works by reducing the overall emissions. What causes this problem with the Secondary Air Injection System Switching Valve Stuck Closed Bank 1? Faults in the one-way check valve.

Where is the secondary air pump relay located? ›

It's located in the electrical box in the engine bay under the right side air filter.

How do you test a secondary air injection? ›

The secondary air valve can be quickly inspected in an easy way:
  1. Loosen the connecting hose on the secondary air non-return valve leading to the secondary air pump. ...
  2. If there are deposits on this side of the valve (finger test, see Fig. ...
  3. Inspect the secondary air pump and replace it if necessary.

How do I know if my air pump is working? ›

Usually, a failed air pump will produce a few noticeable symptoms that can alert the driver that the vehicle requires attention.
  1. Engine is running rough. One of the first symptoms of a bad or failing smog pump is a rough running engine. ...
  2. Reduced horsepower. ...
  3. Check Engine Light comes on.
4 Jan 2016

What happens when you remove a smog pump? ›

The tube into the head would rust through and sound like a bad exhaust leak. As for removing the pump, you won't pass the visual portion of the inspection if you do remove it. I ripped off my smog stuff a long time ago just because I got bored and don't have emissions.

How much does it cost to replace a secondary air injection pump? ›

If it is broken, then you need to replace it as quickly as possible. Overall, repairing a secondary air injection system will cost you around $450. This cost is split between the cost of parts and the cost of labor. New parts will cost about $250 while labor will usually cost another $150-$200.

What does the air pump relay do? ›

The relay controls the high current flow to the AIR injection pump integral bypass valve. This allows the PCM driver to only have to control the relatively low current used by the relay.

How long do secondary air pumps last? ›

This pump runs for approximately 30-120 seconds following start-up and is operated upon electrical request from a vehicle's ECM/PCM. This additional airflow is used to further neutralize a vehicle's noxious emissions, especially in conjunction with exceedingly rich operating conditions.

What does air injection check valve do? ›

The AIR check valve prevents reverse exhaust flow from entering the AIR system. If the check valve fails, hot exhaust gases can sneak back into the system, damaging components, such as the air pump and air management valves.

What is secondary air injection system incorrect flow? ›

Secondary Air Injection Incorrect Flow Detected

Diagnostic Fault Code P0411 is indicative of a general lack of flow from a vehicle's secondary air injection circuit. In turn, this lack of airflow is registered by the affected vehicle's O2 sensors and is recorded by the PCM/ECM as a diagnostic fault.

Can an air pump overheat? ›

When an air compressor overheats, the problem is typically related to factors involving irregular suction or discharge pressure. Alternately, the problem could stem from insufficient ventilation, eroded oil or any given number of issues related to the wear and tear of machine parts.

What is the purpose of connecting the air injection system to the catalytic converter? ›

The catalytic converter needs two elements the EGR system and air injection systems provide: proper temperatures to reduce NOx and oxygen to burn hydrocarbons. Under ideal conditions, a three-way catalyst can reduce somewhere between 50% and 95% of NOx emissions and 99.9% of the unburned fuel.

What causes P2440? ›

What Does P2440 Mean? Typically, P2440 is tripped because the Bank #1 Pressure Sensor detects pulsation of exhaust gas despite ECM commanding the Air Switching Valve to close. Meaning the Switching Valve is Stuck Open.

What does P2444 mean? ›

P2444 code definition

The P2444 diagnostic trouble code is an indication that the bank 1 secondary air injection system pump is stuck.

What would be a concern if the SAI one way check valve was stuck open? ›

If a P2442 code comes up, a one-way check valve is stuck open in the secondary air injection system, causing too much airflow into the exhaust and allowing hot exhaust gas to travel back into the pump. If the PCM receives a voltage reading of more than 10% of the allowed amount the P2442 code will be stored.

What is secondary air injection control circuit? ›

The secondary air injection system assists with reducing a vehicle's emissions by pumping air into the exhaust stream when an engine is cold, which helps speed up the process of warming the catalytic converter. This code most often appears in cold weather.

What is code P2431 mean? ›

If your car is showing the P2431 engine code, it means that your secondary air system, which pumps fresh air into the exhaust to reduce vehicle emissions, has a problem. An incorrect airflow has been detected, and you should get it fixed promptly to avoid a failed emissions test.

How much does it cost to fix a secondary air injection? ›

Overall, repairing a secondary air injection system will cost you around $450. This cost is split between the cost of parts and the cost of labor. New parts will cost about $250 while labor will usually cost another $150-$200.

How do you clean a secondary air injection system? ›

The basic procedure is to put solvent and compressed air into the SAI system on the top of the engine and clean the ports from the bottom until air runs freely through the passages. The supplies you will need two bottle of carburetor cleaner.

Where is the secondary air injection pump located? ›

The secondary air injection pump is usually located on the engine or at least in the engine bay. It can sometimes be hidden deep into the engine bay, but mostly you will find it installed pretty visible on the engine.

Where is the secondary air valve located at? ›

Secondary air valves are an integral part of the secondary air system. They are fitted between the secondary air pump (1) and exhaust manifold. They prevent pressure peaks in the exhaust flow from damaging the secondary air system and exhaust gas or condensate from entering the secondary air pump.

How do I know if my secondary air pump is working? ›

Check Engine Light

One of the most common symptoms of a bad secondary air system is that the Check Engine Light will come on. This light comes on when there is a problem with the engine, and it can be triggered by a variety of issues, including a failing secondary air injection pump.

Does the secondary air pump run all the time? ›

During a cold start, the secondary air pump may only be in operation for a maximum of 90 – 120 seconds. The secondary air pump is not designed for continuous use!

What turns on the secondary air pump? ›

How Does Secondary Air Injection Work? - YouTube

What is a secondary air injection switching valve? ›

The secondary-air shut-off valve ensures that secondary-air is only routed to the exhaust manifold in the cold starting phase. Secondary-air valves are either actuated by a vacuum controlled by a solenoid switching valve or open in response to the pressure of the secondary-air pump.

What does secondary air injection system incorrect flow mean? ›

Secondary Air Injection Incorrect Flow Detected

Diagnostic Fault Code P0411 is indicative of a general lack of flow from a vehicle's secondary air injection circuit. In turn, this lack of airflow is registered by the affected vehicle's O2 sensors and is recorded by the PCM/ECM as a diagnostic fault.

What does an air injection check valve do? ›

The AIR check valve prevents reverse exhaust flow from entering the AIR system. If the check valve fails, hot exhaust gases can sneak back into the system, damaging components, such as the air pump and air management valves.

How do I know if my air pump is working? ›

Usually, a failed air pump will produce a few noticeable symptoms that can alert the driver that the vehicle requires attention.
  1. Engine is running rough. One of the first symptoms of a bad or failing smog pump is a rough running engine. ...
  2. Reduced horsepower. ...
  3. Check Engine Light comes on.
4 Jan 2016

What does secondary air injection do? ›

Secondary air injection (commonly known as air injection) is a vehicle emissions control strategy introduced in 1966, wherein fresh air is injected into the exhaust stream to allow for a fuller secondary combustion of exhaust gases.

Where does a secondary air injection system deliver its air supply when the engine is at operating temperature? ›

The secondary air pump must draw in ambient air and inject it into the exhaust gas manifold downstream of the exhaust valves.

How do you know when a check valve is bad? ›

The signs of a failing swing check valve are often audible. When the disc opens and closes repeatedly (because of low-pressure flow) or violently (because of water hammer), it emits a tapping or hammering sound, respectively.

What happens when you remove a smog pump? ›

The tube into the head would rust through and sound like a bad exhaust leak. As for removing the pump, you won't pass the visual portion of the inspection if you do remove it. I ripped off my smog stuff a long time ago just because I got bored and don't have emissions.

How long should a check valve last? ›

While typical component lifespans are application specific, manufacturers suggest metal and plastic check valves should be replace every 5-7 years whereas check valves manufactured from rubber may remain fully serviceable for up to 35-50 years.

Videos

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