Owning a Toyota Tundra means relying on a truck built for strength, durability, and performance. However, even the most dependable vehicles can experience issues over time — and one of the most talked-about problems among Tundra owners has been the Toyota Tundra secondary air injection pump recall.
This recall affected thousands of Tundra models and was related to a critical emissions component that, when malfunctioning, could lead to costly repairs and performance issues. Understanding this recall helps owners know whether their vehicle is affected and what steps they can take to fix it.
In This Article
Toyota Tundra Secondary Air Injection Pump Recall
The Toyota Tundra secondary air injection pump recall revolves around a defect in the system that controls emissions during engine startup. The secondary air injection pump (SAIP) is designed to help reduce pollutants by injecting fresh air into the exhaust system. Unfortunately, early designs were prone to moisture intrusion, causing corrosion and pump failure.
Toyota acknowledged that the issue could trigger the Check Engine Light and place the vehicle into limp mode, reducing engine power dramatically. This left many drivers frustrated — especially those relying on their Tundra for towing, hauling, or work use.
In response, Toyota launched a service campaign and extended warranty coverage for affected vehicles to repair or replace the faulty components at no cost to the owner. This recall underscored Toyota’s commitment to addressing known issues, but it also raised questions about the design and reliability of the air injection system.
What Is the Secondary Air Injection Pump in a Toyota Tundra?
Before diving deeper into the recall details, it helps to understand what this part does. The secondary air injection pump is part of the vehicle’s emission control system. It injects clean, pressurized air into the exhaust manifold right after engine startup. The goal is to burn off uncombusted fuel particles more efficiently, ensuring lower emission levels until the catalytic converter heats up.
Here’s a quick overview of the system’s main components:
| Component | Function |
| Secondary Air Injection Pump | Pushes fresh air into the exhaust to reduce emissions during cold starts. |
| Air Switching Valves (ASV) | Directs airflow between the pump and exhaust manifold. |
| Pressure Sensors & Relays | Monitor airflow and control timing for the system. |
| Vacuum Lines & Hoses | Carry air from the pump to various parts of the exhaust. |
When everything functions correctly, this system runs silently in the background. But if the pump or valves fail, it can trigger error codes such as P0418, P2440, or P2442, signaling a malfunction in the secondary air system. In some cases, the truck will automatically restrict power to prevent damage — a frustrating experience for owners.
Common Symptoms of a Faulty Secondary Air Injection Pump
Many Toyota Tundra owners first learned about this problem when their trucks suddenly began acting up. Recognizing the early symptoms of secondary air injection pump failure can help prevent more serious issues.
Here are the most frequent warning signs:
- Check Engine Light (CEL) appears with specific air injection system codes.
- Reduced engine power or “limp mode.” The truck may accelerate sluggishly or cap out at a low RPM.
- Rough cold starts or louder exhaust noises immediately after startup.
- Decreased fuel efficiency, as the engine struggles to manage emissions effectively.
- Water or condensation inside the air pump, visible during inspection.
A common real-world scenario involves the pump filling with moisture due to poor drainage. Over time, the water corrodes the internal components, leading to total system failure. Once this happens, replacement can cost anywhere from $1,000 to $2,500 out of pocket — unless covered by recall or warranty.
“It started with a simple check engine light,” shared a 2010 Tundra owner from Texas. “Then the truck lost power on the freeway. The dealership diagnosed a failed secondary air pump — luckily, Toyota covered it under the extended warranty.”
These symptoms became widespread enough for Toyota to take official action, launching the Toyota Tundra secondary air injection pump recall to resolve the defect and prevent further failures.
Causes of the Secondary Air Injection Pump Failure in Toyota Tundra
The failure of the secondary air injection pump in Toyota Tundra models wasn’t random — it stemmed from a clear design flaw that made the system vulnerable to water and debris intrusion.
The air injection system draws in fresh air from outside the engine bay. However, in certain Tundra models, the intake location was poorly shielded, allowing moisture, dirt, and even small insects to enter the pump. Over time, this led to corrosion, short-circuiting, or complete mechanical failure.
Here are the most common causes that led to pump damage:
- Water Ingress – The most frequent issue. Rain or humidity could easily enter the air pump assembly.
- Corroded Valves – Stuck or corroded air switching valves prevented proper airflow, overloading the pump.
- Electrical Failures – Corrosion inside connectors caused false sensor readings or total pump shutdown.
- Design Weakness – Early-generation Tundra models used a pump housing that lacked proper sealing and drainage.
Toyota engineers later revised the design to include improved seals and water-resistant materials. However, the earlier models remained vulnerable, and that’s what ultimately triggered the Toyota Tundra secondary air injection pump recall.
In many cases, simply replacing the pump wasn’t enough. The entire system — including switching valves and sensors — needed inspection or replacement to prevent recurrence.
Overview of the Toyota Tundra Secondary Air Injection Pump Recall
Toyota officially acknowledged the problem and initiated a service campaign and recall to fix it. The recall covered certain Toyota Tundra models equipped with the 4.7L and 5.7L V8 engines, where moisture exposure could disable the air injection system and cause the truck to enter a reduced-power mode.
The main goals of the recall were:
- To inspect and replace faulty air injection pumps and valves.
- To upgrade or reroute air intake components to reduce water exposure.
- To extend the emissions warranty for affected owners.
Toyota did not issue a “safety recall” in the traditional sense but rather a Limited Service Campaign (LSC) — specifically campaigns LSC ZE7, ZE8, and ZH2 in some regions. These campaigns acted as warranty extensions rather than federal recalls, meaning that repairs were done free of charge at participating dealerships within certain time or mileage limits.
The National Highway Traffic Safety Administration (NHTSA) also documented owner complaints related to this issue, which added public pressure for Toyota to take stronger corrective action.
Toyota’s fix involved upgrading the pump and valve assemblies and in some cases, reprogramming the vehicle’s ECU to handle startup emissions more effectively. Owners who had already paid for repairs before the campaign could also apply for reimbursement, which helped build goodwill among affected drivers.
List of Toyota Tundra Model Years Affected by the Recall
Not every Toyota Tundra was affected, but a significant range of production years fell under the recall or extended warranty. The problem was primarily found in 2007 through 2013 Toyota Tundra models with V8 engines.
Here’s a breakdown of the most affected model years:
| Model Year | Engine Type | Recall/Warranty Campaign Code | Status |
| 2007 Tundra | 4.7L / 5.7L V8 | LSC ZE7 | Eligible for replacement |
| 2008 Tundra | 4.7L / 5.7L V8 | LSC ZE8 | Eligible for replacement |
| 2009 Tundra | 4.7L / 5.7L V8 | LSC ZE8 | Eligible for replacement |
| 2010 Tundra | 4.6L / 5.7L V8 | LSC ZH2 | Extended warranty only |
| 2011–2013 Tundra | 4.6L / 5.7L V8 | LSC ZH2 | Coverage varies by VIN |
While these are the most commonly cited model years, Toyota advised all owners to check their vehicle’s VIN number through the official recall lookup page to confirm coverage. Some vehicles outside this range were included depending on production date and emissions equipment configuration.
Tip: You can verify whether your truck is affected by visiting Toyota’s official recall lookup page and entering your VIN.
This step ensures you don’t pay out of pocket for a repair that Toyota may already cover under warranty or recall.
What Toyota Offered in the Secondary Air Injection Pump Recall Program
When reports of secondary air injection pump failure began to surge, Toyota responded with a warranty enhancement program designed to protect affected Tundra owners. Rather than issuing a federal recall, Toyota created a Limited Service Campaign (LSC) that provided free inspection and repair for eligible vehicles.
Here’s what Toyota offered through the program:
- Free repair or replacement of the secondary air injection pump and related components if failure occurred within the warranty period.
- Extended warranty coverage — often up to 10 years or 150,000 miles from the vehicle’s first use date, depending on the campaign code.
- ECU reprogramming to optimize the air injection system’s performance and reduce false error triggers.
- Reimbursement for owners who previously paid out-of-pocket for pump or valve replacement before the campaign started.
Toyota dealerships were instructed to inspect the system for moisture damage, check for fault codes, and replace affected parts as necessary. The coverage applied even if the vehicle was outside the original powertrain warranty, offering a major relief to long-term owners.
According to Toyota’s service bulletin, the campaign aimed to “enhance customer satisfaction” by addressing a known design issue that could lead to engine performance loss or reduced emissions compliance.
This goodwill action helped restore confidence among Tundra owners, though some still reported repeat issues even after the recall repair — a reminder that regular maintenance and system inspection remain essential.
How to Check if Your Toyota Tundra Is Affected by the Recall
If you’re unsure whether your truck falls under the Toyota Tundra secondary air injection pump recall, checking is quick and straightforward. All you need is your Vehicle Identification Number (VIN) — a unique 17-character code found on your registration, dashboard, or driver-side door jamb.
Steps to Check Recall Status:
- Locate your VIN.
It’s printed on your vehicle registration, insurance card, or visible at the bottom of the windshield on the driver’s side. - Visit Toyota’s official recall lookup page:
Go to Toyota.com/recall. - Enter your VIN and submit.
The system will instantly show whether your Tundra has an open recall, service campaign, or warranty extension. - Contact your local Toyota dealership.
If your truck qualifies, schedule an appointment for inspection and repair. - Keep all records.
Maintain copies of recall letters, invoices, and warranty extensions in case of future issues or resale.
Pro Tip:
Even if your recall appears closed, Toyota sometimes issues secondary service bulletins or new campaigns for the same issue. It’s worth rechecking your VIN every few months, especially if you notice symptoms like the check engine light or reduced power mode.
The Repair Process for the Secondary Air Injection Pump Recall
Once your Toyota Tundra is confirmed as part of the recall or warranty program, the repair process begins at an authorized dealership. Depending on the condition of your system, the repair could involve anything from a software update to full component replacement.
What Happens During the Recall Service:
- Diagnostic Scan:
The technician checks for air injection–related trouble codes (P0418, P2440, P2442, etc.) using Toyota’s diagnostic tools. - System Inspection:
The pump, switching valves, and vacuum hoses are inspected for moisture, corrosion, or debris buildup. - Component Replacement:
- If water damage is found, the secondary air injection pump and valves are replaced with redesigned, water-resistant parts.
- Electrical connectors and relays are checked or replaced if corroded.
- Some vehicles also receive updated intake routing to minimize future moisture intrusion.
- If water damage is found, the secondary air injection pump and valves are replaced with redesigned, water-resistant parts.
- ECU Reprogramming:
The engine control unit may be updated with new software to optimize system timing and prevent false warnings. - Final Testing:
The truck undergoes a road test and emissions check to confirm that the system operates correctly and the error codes are cleared.
The repair process usually takes 3 to 6 hours, though it can vary by dealership. If multiple components are affected, the vehicle may need to stay overnight for parts replacement or diagnostic follow-up.
| Service Type | Approx. Time | Cost (if out of warranty) |
| Diagnostic & Inspection | 1–2 hours | $150–$250 |
| Pump Replacement | 3–4 hours | $900–$1,400 |
| Full System Replacement | 5–6 hours | $1,800–$2,500 |
| ECU Update Only | 1 hour | $0 (recall covers) |
Owners who completed the recall repair reported significant performance improvement, smoother startups, and restored engine power.
“After the repair, my 2008 Tundra runs like new again,” said a driver from Colorado. “No more check engine light or limp mode — Toyota handled everything quickly under warranty.”
Owner Experiences and Reported Issues After the Recall
The Toyota Tundra secondary air injection pump recall brought relief to many owners, but experiences after the repair have varied. While most drivers reported significant improvements, a portion continued to experience related issues even after the fix.
Positive Feedback from Owners
Many Tundra owners expressed satisfaction with how Toyota handled the issue. They appreciated the free repair and extended warranty coverage, especially for a component that could easily cost thousands of dollars to replace.
Common feedback included:
- Noticeably smoother startups and quieter engine operation after the pump replacement.
- No more limp mode or restricted acceleration after recall repair.
- Improved fuel economy and better throttle response.
- Professional and fast service at authorized Toyota dealerships.
“Toyota replaced both the air pump and valves under the LSC campaign, no charge. My 2011 Tundra has run perfectly ever since.” — Verified owner, Arizona
Reported Problems After Repair
However, not all experiences were perfect. A few owners reported recurring check engine lights or valve failure within a few years of repair. In some cases, dealerships replaced only part of the system, leaving older valves or sensors vulnerable to new failure.
Typical post-repair complaints included:
- Repeat error codes (P0418, P2442) despite pump replacement.
- Incomplete diagnosis, requiring return visits.
- Moisture-related issues resurfacing in humid or rainy climates.
Toyota has since improved replacement parts with better sealing and drainage, significantly reducing recurrence rates. Still, periodic inspections and preventive maintenance are essential to ensure long-term reliability.
Cost of Secondary Air Injection Pump Replacement (If Out of Warranty)
For Tundra owners no longer covered by the recall or warranty extension, replacing the secondary air injection pump can be an expensive repair. Because it’s part of the emission control system, replacement involves labor-intensive disassembly and specialized parts.
Below is a breakdown of average replacement costs across U.S. repair shops:
| Repair Type | Average Cost (USD) | Parts Included |
| Replace Air Injection Pump Only | $900 – $1,200 | Pump, gasket, seals |
| Replace Pump + Valves | $1,400 – $2,000 | Pump, valves, hoses |
| Full System Replacement | $1,800 – $2,500 | Complete kit + labor |
| Aftermarket Pump Only | $400 – $700 | Pump only (non-OEM) |
Labor cost accounts for nearly half the expense, since the pump is located under the intake manifold — requiring partial disassembly of the engine’s upper section.
If you’re out of warranty, it’s still worth contacting Toyota directly or your local dealer. Some have been known to offer goodwill assistance for owners with full service records or low mileage.
OEM vs. Aftermarket Parts
- OEM (Toyota Genuine) parts are more durable and guaranteed to meet emissions standards.
- Aftermarket kits are cheaper but may lack water resistance, potentially shortening their lifespan.
- A few brands (e.g., Dorman, Cardone) offer improved designs, but performance varies by supplier.
If you plan to keep your Tundra long-term, OEM replacements are strongly recommended to avoid repeat failures.
Preventative Maintenance for Toyota Tundra Secondary Air Injection Pump
Even after the recall repair, preventive care can help extend the life of your secondary air injection pump system. This system operates primarily during cold starts, making it sensitive to moisture and debris buildup.
Here are practical maintenance tips to protect your Tundra:
Regular Maintenance Steps
- Inspect air pump inlets every 6–12 months for signs of dirt or water accumulation.
- Avoid deep water crossings or high-pressure washing near the engine bay.
- Clean or replace intake filters if your truck operates in dusty or humid conditions.
- Check electrical connectors for corrosion — especially after heavy rain or car washes.
- Run diagnostic scans occasionally using an OBD-II tool to catch early error codes.
Suggested Modifications
Some Tundra owners have added aftermarket air pump bypass kits or intake relocation hoses to reduce water intrusion. However, these should be used cautiously and in compliance with emissions regulations.
Ideal Operating Habits
- Let the engine idle for a few seconds before driving off, giving the system time to run its short cleaning cycle.
- Keep up with scheduled oil changes, as poor engine health can increase exhaust contaminants.
Preventive maintenance may seem minor, but it’s a key factor in keeping your emissions system efficient and avoiding expensive repeat failures.
Legal and Warranty Implications of the Toyota Tundra Secondary Air Injection Pump Recall
The Toyota Tundra secondary air injection pump recall was officially categorized as a Limited Service Campaign (LSC) rather than a safety recall under federal law. That distinction matters because it affects how long Toyota is legally required to offer repairs and what rights owners have.
Warranty Coverage and Rights
Under the Emissions Control Warranty, Toyota is required by federal regulations to cover certain emission-related parts for at least 8 years or 80,000 miles. However, the company voluntarily extended coverage up to 10 years or 150,000 miles for the secondary air injection system in specific models — a generous step beyond the legal minimum.
If your vehicle’s issue occurred outside that coverage, you still have options:
- Request a goodwill repair: Some dealerships approve cost-sharing or full coverage for long-term customers or vehicles with full service histories.
- File a complaint with NHTSA: If the defect poses a safety concern or reoccurs after repair, you can file a report at NHTSA.gov.
- Seek reimbursement: If you paid for a repair before the campaign started, you may still be eligible for retroactive reimbursement under Toyota’s service campaign policies.
Legal Precedents
Some owners joined class-action efforts alleging that Toyota knew about the defect earlier than it disclosed. While no widespread settlement was approved specifically for the Tundra SAIP issue, these cases encouraged Toyota to provide more transparent warranty communication and faster response times for emissions-related problems.
For most owners, the recall process was straightforward — and Toyota’s proactive warranty extensions helped avoid larger legal disputes.
Toyota’s Broader Efforts on Emission System Reliability
The secondary air injection pump issue wasn’t isolated to the Tundra. Toyota also faced similar problems with the Sequoia, Land Cruiser, and Lexus LX 570, which share similar V8 powertrains and air injection systems.
How Toyota Responded
- Redesigned air pump housings and valves to improve water resistance.
- Introduced ECU updates to reduce system strain during cold starts.
- Launched broader service campaigns across multiple models under the Emissions Warranty Enhancement Program.
- Improved dealer training and diagnostic tools to detect early-stage pump failure before limp mode activates.
Toyota’s response demonstrated its long-term commitment to reliability and environmental compliance. By addressing the design flaw and strengthening warranty coverage, the brand maintained the trust of its loyal truck owners.
Impact on the Toyota Tundra’s Reputation
Despite this setback, the Tundra continues to hold a strong reputation for toughness and longevity. Many owners report over 200,000 miles of reliable service once the air injection issue is resolved — proof that a single component issue didn’t define the truck’s overall dependability.
“After Toyota fixed the air pump, my 2010 Tundra has been unstoppable. I’m at 230,000 miles now — still towing and running great.” — Owner review, Oregon
Conclusion: What the Toyota Tundra Secondary Air Injection Pump Recall Means for Owners
The Toyota Tundra secondary air injection pump recall serves as a reminder that even highly engineered trucks can encounter unexpected design challenges. The issue, while frustrating, was ultimately addressed through Toyota’s extended warranty program and updated components.
For Tundra owners, the key takeaways are:
- Check your VIN regularly for open recalls or warranty extensions.
- Act promptly if you notice warning lights, limp mode, or unusual startup noises.
- Maintain your air injection system by keeping the intake area clean and protected from moisture.
- Keep service records, as they can help you qualify for goodwill repairs or reimbursement later.
While the recall caused concern among some drivers, Toyota’s response reflected responsibility and customer care. With the updated system and preventive maintenance, most Tundra owners can continue to enjoy the power, capability, and reliability that made this truck a top choice for years.
For more detailed recall verification or to check current campaigns, visit the official Toyota recall website.
✅ Pro Tip: If you own a 2007–2013 Toyota Tundra and haven’t yet confirmed your recall status, don’t wait — schedule a free inspection today. A small step now can save thousands in future repairs and keep your truck performing at its best.
When he’s not working his magic under the hood, Ethan Wilson is usually sharing his love for Toyota cars through his writing. Ethan’s got a special talent for breaking down complex car topics into easy-to-understand articles, making him a go-to source for Toyota enthusiasts everywhere.