Hi all,
I figured I should post this in case others run into the same problem as me in the future.
I bought an 06 LX470 with 96k miles last month from a Lexus dealer. Long story short, the secondary air induction system pump failed with code p2445 (Secondary Air Injection System Pump Stuck OFF Bank 1) within 2 weeks of picking up the truck and after putting less than 200 miles on it.
I took it over to the dealership to get it checked to confirm what my code reader said and to make sure they hadn't left a hose disconnected or something when they did the 90k mile service (this service was conducted as a part of the purchase agreement). They told me it was $3300 to replace the system.
The service manager went to bat for me (he thought they should just fix it for me given that I had hardly driven it) but ultimately the dealer said they weren't going to cover it. I got Lexus involved and after a couple of weeks and some arm twisting, the dealer offered to cover 1/3 the cost. I said thanks, but no thanks.
It looks to me like I can pick up the pump and 3 valves the dealer wanted to replace for about $800. And it doesn't look like it's more than about 5-6 hours of labor to get it done. It's more than I'm going to do myself but it looks like a pretty straightforward repair for most shops.
However, before I dropped a bunch of cash to fix it, I decided to order one of the bypass kits for the 4.7L: http://www.tundrasolutions.com/foru...292473-ultimate-aip-bypass-model-new-version/
I chose that module (there are 2 options out there along with a DIY solution) because the other one being sold requires cutting into the factory wiring harness. I just wasn't comfortable with that.
Installing the plug itself was obviously very easy. You just unplug the air sensor harness on the intake and plug the module in the middle.
I tried to keep it as "low profile" as possible so I ended up attaching the module with some heavy duty velcro up underneath the diagnostics port on the passenger side. There are lots of other wires and cables running around there so unless you know what you're looking for, it looks relatively stock, IMO.
I drove around like this for a couple of days and sure enough, I'm now "green" across the board for the OBD emissions tests. I've got to say that my OBDLink MX code reader and the Torque Pro app have paid for themselves a couple of times over at this point.
However, the guy that makes the module recommends installing the block-off plates (even though it's not technically required for code p2445) to physically block off the system and ensure that hot exhaust gasses don't work their way past the valves and set off other codes.
In the tundras, it looks like you can just reach around behind the engine with a socket wrench, loosen the bolts on the flange where the AIP system connects in to the rear of the manifold, and slide the block-off plates in. That wasn't working for me. The only nut I could physically get to from the top was the outside passenger side of the flange.
My solution was to come at it from underneath the engine. I had to pull off the big plastic guard (8 12mm bolts) to get some working room. Then I sprayed everything down with PB Blaster and let it sit. I came back with an open 10mm wrench and was able to break each of the 4 nuts loose. I backed them off a few turns by hand and was then able to slide the block-off plates in place.
Tighten the flanges back up, reinstall the engine cover and Bob's your uncle.
I've heard that the AIP system is really the only "weakness" of the 06/07 100's and I certainly agree with that. The cost to replace this system at the dealer is ridiculous. However, the bypass modules seem to work great and while the block-off plates were a bit of a pain, it's really not a difficult install overall.
So my advice is this: I wouldn't let potential AIP issues scare anybody off of an 06/07. However, be aware that these systems do fail and if you want to bring it back to stock condition, the fix is expensive. If you're OK with bypassing the AIP system, then there are several options out there for ~$150 and 30 minutes of your time.
Personally if I was buying another 06/07, one of the first things I'd install would be this bypass system just to prevent any issues from cropping up in the first place. When the system fails it can force your truck into limp mode (it did for me) and sets off the CEL and VRSC lights on the dash. If this happened while you were out in the boonies and didn't have a way to reset it, it could potentially be a real problem. So in my view, the module is a great way to prevent that from ever being an issue.
I figured I should post this in case others run into the same problem as me in the future.
I bought an 06 LX470 with 96k miles last month from a Lexus dealer. Long story short, the secondary air induction system pump failed with code p2445 (Secondary Air Injection System Pump Stuck OFF Bank 1) within 2 weeks of picking up the truck and after putting less than 200 miles on it.
I took it over to the dealership to get it checked to confirm what my code reader said and to make sure they hadn't left a hose disconnected or something when they did the 90k mile service (this service was conducted as a part of the purchase agreement). They told me it was $3300 to replace the system.
The service manager went to bat for me (he thought they should just fix it for me given that I had hardly driven it) but ultimately the dealer said they weren't going to cover it. I got Lexus involved and after a couple of weeks and some arm twisting, the dealer offered to cover 1/3 the cost. I said thanks, but no thanks.
It looks to me like I can pick up the pump and 3 valves the dealer wanted to replace for about $800. And it doesn't look like it's more than about 5-6 hours of labor to get it done. It's more than I'm going to do myself but it looks like a pretty straightforward repair for most shops.
However, before I dropped a bunch of cash to fix it, I decided to order one of the bypass kits for the 4.7L: http://www.tundrasolutions.com/foru...292473-ultimate-aip-bypass-model-new-version/
I chose that module (there are 2 options out there along with a DIY solution) because the other one being sold requires cutting into the factory wiring harness. I just wasn't comfortable with that.
Installing the plug itself was obviously very easy. You just unplug the air sensor harness on the intake and plug the module in the middle.
I tried to keep it as "low profile" as possible so I ended up attaching the module with some heavy duty velcro up underneath the diagnostics port on the passenger side. There are lots of other wires and cables running around there so unless you know what you're looking for, it looks relatively stock, IMO.
I drove around like this for a couple of days and sure enough, I'm now "green" across the board for the OBD emissions tests. I've got to say that my OBDLink MX code reader and the Torque Pro app have paid for themselves a couple of times over at this point.
However, the guy that makes the module recommends installing the block-off plates (even though it's not technically required for code p2445) to physically block off the system and ensure that hot exhaust gasses don't work their way past the valves and set off other codes.
In the tundras, it looks like you can just reach around behind the engine with a socket wrench, loosen the bolts on the flange where the AIP system connects in to the rear of the manifold, and slide the block-off plates in. That wasn't working for me. The only nut I could physically get to from the top was the outside passenger side of the flange.
My solution was to come at it from underneath the engine. I had to pull off the big plastic guard (8 12mm bolts) to get some working room. Then I sprayed everything down with PB Blaster and let it sit. I came back with an open 10mm wrench and was able to break each of the 4 nuts loose. I backed them off a few turns by hand and was then able to slide the block-off plates in place.
Tighten the flanges back up, reinstall the engine cover and Bob's your uncle.
I've heard that the AIP system is really the only "weakness" of the 06/07 100's and I certainly agree with that. The cost to replace this system at the dealer is ridiculous. However, the bypass modules seem to work great and while the block-off plates were a bit of a pain, it's really not a difficult install overall.
So my advice is this: I wouldn't let potential AIP issues scare anybody off of an 06/07. However, be aware that these systems do fail and if you want to bring it back to stock condition, the fix is expensive. If you're OK with bypassing the AIP system, then there are several options out there for ~$150 and 30 minutes of your time.
Personally if I was buying another 06/07, one of the first things I'd install would be this bypass system just to prevent any issues from cropping up in the first place. When the system fails it can force your truck into limp mode (it did for me) and sets off the CEL and VRSC lights on the dash. If this happened while you were out in the boonies and didn't have a way to reset it, it could potentially be a real problem. So in my view, the module is a great way to prevent that from ever being an issue.
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