Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - 1GR-FE ENGINE CONTROL

DTC No.	DTC Detection Condition	Trouble Area
P2444	Secondary air pressure is higher than 3 kPa (23 mmHg) despite the ECM commanding the air pump to turn off (2 trip detection logic).	Short in air pump circuit Open or short in pressure sensor circuit Pressure sensor Air injection control driver ECM
P2445	Secondary air pressure is below 1 kPa (8 mmHg) despite the ECM commanding the air pump to turn on (2 trip detection logic).	Air pump assembly Open in air pump circuit Air injection system piping Pressure sensor Open or short in pressure sensor circuit Air injection control driver ECM Open or short in air pump heater circuit Air pump heater relay (AI-PMP HTR)
	When secondary air injection is turned from off to on, the change in the secondary air injection pressure is less than 5 kPa (2 trip detection logic).
	When secondary air injection is on, the amount of air from the air pump is below the threshold (2 trip detection logic).
P2447	When secondary air injection is on, the amount of air from the air pump is below the threshold (2 trip detection logic).

MONITOR DESCRIPTION

The ECM monitors the pressure in the secondary air passage using the pressure sensor located on the emission control valve set of the secondary air injection system. The sensor measures the pressure in the secondary air passage and transmits a signal to the ECM.

If a malfunction is detected, the ECM illuminates the MIL and stores a DTC.

Example:

DTC P2444 mainly indicates a malfunction in which the air pump is stuck on.

DTC P2445 and P2447 mainly indicate a malfunction in which the air pump is stuck off.

WIRING DIAGRAM

Refer to DTC P0412 ().

INSPECTION PROCEDURE

HINT:

By using the GTS to perform the Secondary Air Injection Check operation in the System Check, the air-fuel ratio and the pressure in the secondary air injection system passage can be checked while the secondary air injection system is operating. This helps technicians to troubleshoot the system when it malfunctions. Furthermore, pending codes also can be checked by performing Utility / Secondary Air Injection Check / Automatic Mode after the repair.

Read freeze frame data using the GTS. Freeze frame data records the engine condition when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred.

1.CHECK FOR ANY OTHER DTCS OUTPUT (IN ADDITION TO DTC P2444, P2445 AND/OR P2447)

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

Turn the GTS on.

Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.

Read the DTCs.

Result
Result	Proceed to
P2444, P2445 and/or P2447 is output	A
P2444, P2445 and/or P2447 and P0418 are output	B
P2444, P2445 and/or P2447 and other DTCs (except P0418) are output	C

HINT:

If any DTCs other than P0418, P2444, P2445 and P2447 are output, troubleshoot those DTCs first.

GO TO AIR PUMP INSPECTION PROCEDURE ()

GO TO DTC CHART ()

A

2.CHECK FREEZE FRAME DATA (AIR PUMP FREEZE, AIR SWITCHING VALVE FREEZE AND AIR SWITCHING VALVE2 FREEZE)

Connect the GTS to the DLC3.

Turn the ignition switch to ON and turn the GTS on.

Read the values of Air Pump Freeze, Air Switching Valve Freeze and Air Switching Valve2 Freeze from the freeze frame data recorded previously.

Referring to the following table, proceed to the appropriate step according to the result of the data reading.

Result
Result			Proceed to
Air Pump Freeze	Air Switching Valve Freeze	Air Switching Valve2 Freeze	Proceed to
OFF	OFF	OFF	B
Except above			A

Go to step 8

A

3.PERFORM ACTIVE TEST USING GTS (ACTIVATE THE AIR PUMP HEATER)

Dtc P2444 Secondary Air Injection System Pump Stuck On Bank1. 1GR-FE ENGINE CONTROL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Disconnect the air pump connector.

Connect the GTS to the DLC3.

Turn the ignition switch to ON and turn the GTS on.

Enter the following menus: Powertrain / Engine and ECT/ Active Test / Activate the Air Pump Heater.

Measure the voltage according to the value(s) in the table below.

Tester Connection Condition Specified Condition
C139-1 - Body ground Activate the Air Pump Heater is ON 11 to 14 V

Text in Illustration
*a	Front view of wire harness connector (to Air Pump Assembly)

Reconnect the air pump connector.

Go to step 5

OK

4.INSPECT AIR PUMP ASSEMBLY (HEATER RESISTANCE)

Inspect the air pump assembly ().

REPLACE AIR PUMP ASSEMBLY ()

OK

5.INSPECT AIR PUMP HEATER RELAY (AI-PMP HTR)

Inspect the air pump heater relay (AI-PMP HTR) ().

REPLACE AIR PUMP HEATER RELAY (AI-PMP HTR)

OK

6.CHECK AIR PUMP HEATER RELAY (AI-PMP HTR) (POWER SOURCE)

Remove the air pump heater relay (AI-PMP HTR).

Measure the voltage according to the value(s) in the table below.

Standard Voltage:
Tester Connection Condition Specified Condition
Air pump heater relay (AI-PMP HTR) terminal 5 - Body ground Always 11 to 14 V

Text in Illustration
*1	Engine Room Relay Block
*2	Air Pump Heater Relay (AI-PMP HTR)

Reinstall the air pump heater relay (AI-PMP HTR).

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

7.CHECK HARNESS AND CONNECTOR (AIR PUMP - AIR PUMP HEATER RELAY (AI-PMP HTR), BODY GROUND)

Remove the air pump heater relay (AI-PMP HTR).

Disconnect the air pump connector.

Measure the resistance according to the value(s) in the table below.

Standard Resistance (Check for Open):
Tester Connection Condition Specified Condition
Air pump heater relay (AI-PMP HTR) terminal 3 - C139-1 Always Below 1 Ω
C139-3 - Body ground Always Below 1 Ω

Standard Resistance (Check for Short):
Tester Connection Condition Specified Condition
Air pump heater relay (AI-PMP HTR) terminal 3 or C139-1 - Body ground Always 10 kΩ or higher

Reinstall the air pump heater relay (AI-PMP HTR).

Reconnect the air pump connector.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

8.PERFORM ACTIVE TEST USING GTS (SECONDARY AIR INJECTION SYSTEM OPERATION)

Start the engine and warm it up.

Turn the ignition switch off.

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

Turn the GTS on.

Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Manual Mode / AIR PUMP: ON, ASV1: OPEN, ASV2: OPEN and AIR PUMP: OFF, ASV1: CLOSE, ASV2: CLOSE.

HINT:

When Manual Mode is selected, the GTS initialization (atmospheric pressure measurement) is performed automatically. The initialization takes 10 seconds. After the initialization, AIR PUMP and ASV operation can be selected.

Start the engine.

Perform the secondary air injection system forced operation while the engine is idling.

Check that the Data List values for the air pump (AIR PUMP), emission control valve (ASV) and pressure in the secondary air injection system passage (PRESSURE) displayed on the GTS are as shown in the table below.

Standard:
GTS Operation Air Pump Emission Control Valve PRESSURE*
AIR PUMP: ON, ASV: OPEN ON ON 1 kPa or higher [A]
AIR PUMP: OFF, ASV: CLOSE OFF OFF Below 3 kPa [B]

*: Average pumping pressure. The pressure should be 1 kPa or higher when the secondary air injection system operates.

Standard:
The pressures for [A] and [B] should differ by 1 kPa or more.

Turn the ignition switch off.

NOTICE:

This Secondary Air Injection Check only allows technicians to operate the secondary air injection system for a maximum of 5 seconds. Furthermore, the check can only be performed up to 4 times per trip. If the test is repeated, intervals of at least 30 seconds are required between checks. While secondary air injection system operation using the GTS is prohibited, the GTS display indicates the prohibition (WAIT or ERROR). If ERROR is displayed on the GTS during the test, stop the engine for 10 minutes, and then try again.

Performing Secondary Air Injection Check repeatedly may cause damage to the secondary air injection system. If it is necessary to repeat the check, leave an interval of several minutes between System Check operations to prevent the system from overheating.

When performing the Secondary Air Injection Check operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch turned to ON or the engine running.

Turn the ignition switch off when the Secondary Air Injection Check operation finishes.

Go to step 10

OK

9.CHECK WHETHER DTC OUTPUT RECURS (DTC P2444, P2445 AND/OR P2247)

Start the engine and warm it up.

Turn the ignition switch off.

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

Turn the GTS on.

Clear the DTCs (if stored) ().

Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Automatic Mode.

Start the engine after the GTS initialization is finished.

Perform the System Check operation by pressing ENTER (Next).

Perform the following to confirm the secondary air injection system pending codes: Press the Exit button.

Check for pending DTCs.

Turn the ignition switch off.

NOTICE:

When performing the Secondary Air Injection Check operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch turned to ON or the engine running.

Turn the ignition switch off when the Secondary Air Injection Check operation finishes.

Result
Result	Proceed to
P2444, P2445 and/or P2447 is output	A
No pending DTC is output	B

CHECK FOR INTERMITTENT PROBLEMS ()

A

10.INSPECT EMISSION CONTROL VALVE SET (PRESSURE SENSOR)

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

Turn the GTS on.

Enter the following menus: Powertrain / Engine and ECT / Data List / Air Pump Pressure (Absolute) and Air Pump2 Pressure (Absolute).

Check the pressure displayed on the GTS.

Standard pressure:
45 to 135 kPa

HINT:

The GTS displays the air pump pressure as absolute pressure.

Result
Result	Proceed to
OK	A
NG (for Bank 1)	B
NG (for Bank 2)	C

REPLACE NO. 1 EMISSION CONTROL VALVE SET ()

REPLACE NO. 2 EMISSION CONTROL VALVE SET ()

A

11.CHECK AIR INJECTION SYSTEM PIPE CONNECTIONS

Dtc P2444 Secondary Air Injection System Pump Stuck On Bank1. 1GR-FE ENGINE CONTROL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Check that all the pipes and hoses between the air pump and emission control valve are securely connected.

Inspect the pipes and hoses for blockages and damage.

OK:
Secondary air injection system piping has no blockages or damage.

REPAIR OR REPLACE AIR INJECTION SYSTEM PIPING

OK

12.CHECK HARNESS AND CONNECTOR (AIR INJECTION CONTROL DRIVER POWER SOURCE CIRCUIT)

Disconnect the air injection control driver connectors.

Measure the resistance according to the value(s) in the table below.

Standard Resistance:
Tester Connection Condition Specified Condition
C61-1 (E) - Body ground Always Below 1 Ω

Turn the ignition switch to ON.

Measure the voltage according to the value(s) in the table below.

Standard Voltage:
Tester Connection Condition Specified Condition
C60-1 (BATT) - Body ground Always 11 to 14 V (near battery voltage)
C61-5 (+B) - Body ground Ignition switch ON 11 to 14 V (near battery voltage)

Text in Illustration
*a	Front view of wire harness connector (to Air Injection Control Driver)

Reconnect the air injection control driver connectors.

REPAIR OR REPLACE AIR INJECTION CONTROL DRIVER POWER SOURCE CIRCUIT

OK

13.CHECK HARNESS AND CONNECTOR (ECM - AIR INJECTION CONTROL DRIVER)

Disconnect the ECM connector.

Disconnect the air injection control driver connector.

Measure the resistance according to the value(s) in the table below.

Standard Resistance:
Tester Connection Condition Specified Condition
C45-54 (AIRP) - C61-4 (SIP) Always Below 1 Ω
C61-4 (SIP) - Body ground Always 10 kΩ or higher

Reconnect the ECM connector.

Reconnect the air injection control driver connector.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

14.CHECK AIR PUMP ASSEMBLY

Inspect the air pump assembly ().

Go to step 17

Go to step 15

15.REPLACE AIR PUMP ASSEMBLY

Replace the air pump assembly ().

NEXT

16.CHECK WHETHER DTC OUTPUT RECURS (DTC P2444, P2445 AND/OR P2447)

Start the engine and warm it up.

Turn the ignition switch off.

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

Turn the GTS on.

Clear the DTCs (if stored) ().

Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Automatic Mode.

Start the engine after the GTS initialization is finished.

Perform the System Check operation by pressing ENTER (Next).

Perform the following to confirm the secondary air injection system pending codes: Press the Exit button.

Check for pending DTCs.

OK:
No pending DTC is output.

Turn the ignition switch off.

NOTICE:

When performing the Secondary Air Injection Check operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch turned to ON or the engine running.

Turn the ignition switch off when the Secondary Air Injection Check operation finishes.

Go to step 17

END

17.PERFORM ACTIVE TEST USING GTS

Disconnect the air injection control driver connector.

Connect terminals DI and SIV of the wire harness connector for the air injection control driver.

Text in Illustration
*1	Air Injection Control Driver
*2	ECM
*a	Front view of wire harness connector (to Air Injection Control Driver)

Connect the GTS to the DLC3.

Turn the ignition switch to ON and turn the GTS on.

Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Manual Mode / AIR PUMP: ON, ASV 1: OPEN, ASV 2: OPEN.

HINT:

When Manual Mode is selected, the GTS initialization (atmospheric pressure measurement) is performed automatically. The initialization takes 10 seconds. After the initialization, AIR PUMP and ASV operation can be selected.

Start the engine.

Perform the secondary air injection system forced operation while the engine is idling.

Measure the voltage between the SIV and E terminals of the ECM connector when the secondary air injection system is ON and OFF.

Turn the ignition switch off.

NOTICE:

When performing the Secondary Air Injection Check operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch ON or the engine running.

Turn the ignition switch off when the Secondary Air Injection Check operation finishes.

Standard Voltage:
Tester Connection Condition Specified Condition
C61-3 (SIV) - C61-1 (E) AIR PUMP: ON, ASV: OPEN 0.5 to 2 V
C61-3 (SIV) - C61-1 (E) AIR PUMP: OFF, ASV: CLOSE 11 to 14 V

Connect terminals DI and SIP of the wire harness connector for the air injection control driver.

Text in Illustration
*1	Air Injection Control Driver
*2	ECM
*a	Front view of wire harness connector (to Air Injection Control Driver)

Connect the GTS to the DLC3.

Turn the ignition switch to ON and turn the GTS on.

Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Manual Mode / AIR PUMP: ON, ASV 1: OPEN, ASV 2: OPEN.

HINT:

When Manual Mode is selected, the GTS initialization (atmospheric pressure measurement) is performed automatically. The initialization takes 10 seconds. After the initialization, AIR PUMP and ASV operation can be selected.

Start the engine.

Perform the secondary air injection system forced operation while the engine is idling.

Measure the voltage between the SIP and E terminals of the ECM connector when the secondary air injection system is ON and OFF.

Turn the ignition switch off.

NOTICE:

When performing the Secondary Air Injection Check operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch ON or the engine running.

Turn the ignition switch off when the Secondary Air Injection Check operation finishes.

Standard Voltage:
Tester Connection Condition Specified Condition
C61-4 (SIP) - C61-1 (E) AIR PUMP: ON, ASV: OPEN 0.5 to 2 V
C61-4 (SIP) - C61-1 (E) AIR PUMP: OFF, ASV: CLOSE 11 to 14 V

Reconnect the air injection control driver connector.

REPLACE ECM ()

OK

18.REPLACE AIR INJECTION CONTROL DRIVER

Replace the air injection control driver ().

NEXT

19.CHECK WHETHER DTC OUTPUT RECURS (DTC P2444, P2445 AND/OR P2447)

Start the engine and warm it up.

Turn the ignition switch off.

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

Turn the GTS on.

Clear the DTCs (if stored) ().

Enter the following menus: Powertrain / Engine and ECT / Utility / Secondary Air Injection Check / Automatic Mode.

Start the engine after the GTS initialization is finished.

Perform the System Check operation by pressing ENTER (Next).

Perform the following to confirm the secondary air injection system pending codes: Press the Exit button.

Check for pending DTCs.

OK:
No pending DTC is output.

Turn the ignition switch off.

NOTICE:

When performing the Secondary Air Injection Check operation after the battery cable has been reconnected, wait for 7 minutes with the ignition switch ON or the engine running.

Turn the ignition switch off when the Secondary Air Injection Check operation finishes.

REPLACE ECM ()

END

Tester Connection	Condition	Specified Condition
C139-1 - Body ground	Activate the Air Pump Heater is ON	11 to 14 V

GTS Operation	Air Pump	Emission Control Valve	PRESSURE*
AIR PUMP: ON, ASV: OPEN	ON	ON	1 kPa or higher [A]
AIR PUMP: OFF, ASV: CLOSE	OFF	OFF	Below 3 kPa [B]