Secondary Air Pump - Faulty? VCDS test method...

[lugars4]

Recenly got codes
P1411 (Bank 2 Insufficient Flow),
P0491 (Bank 1 Insufficient Flow).

Got VCDS / Vagcom, so ran an output test.
No sign of vacuum leaks, N112 actuates and can hear both valves moving ok.

Run the "Secondary Air Pump Relay (J299) test.
The test pulses the relay, i can hear the relay, but no air pump.
Is this the correct test? Any way to energise it without a pulse test?

[lugars4]

Opened the fuse box in the einge bay (pain to get last screw at back), and there is one 50A fuse in there, the others smaller.

Testing the relay i feel relay marked 373 working.
Took relay out and tested it, working fine.

Slightly odd, relay is marked and rated for 40A, i can only assume the 50A fuse is supplying the air pump? So relay inst rated correctly? But it works so just an observation.

Must be a bad pump......

[lugars4]

Update;

Tested pump with multimeter and then applying 12V. Dead.

Now to source one.....

079 906 601 E

It is a PIERBURG 7.00216.04

Best price online is coming up at £400 !

Any ideas where to source any better?

[lugars4]

Replaced the pump, see my other thread on my rebuild, carbon clean etc.

The pump was dead, replaced with new one, working fine now.

However...... same two codes are coming back up.
So, coincidently there must be more than one fault with the system. Engine light came on again today.

I've noticed the exhaust flaps rattle on cold start, so i am thinking vacuum leak. They only do it during cold start, left the car for 6 hours and it held vacuum, so i am thinking the leak is in the lines from the solenoid valve N112 to the two air inlet valves......and when actuated the leak occurs, possibly.

Anyone experience a leak in these lines? When i did an output test, i heard a strange noise the first time the valve pulsed, then it sounded like they were moving, but will re-test and look more carefully later.

FAULT CODES FOR REF:

001169 - Secondary Air Injection System: Bank 1
P0491 - 002 - Insufficient Flow - MIL ON
Freeze Frame:
Fault Status: 11100010
Fault Priority: 0
Fault Frequency: 6
Reset counter: 255
Mileage: 106955 km
Time Indication: 0

Freeze Frame:
RPM: 946 /min
Load: 31.8 %
Speed: 0.0 km/h
Temperature: 21.0°C
Temperature: 13.0°C
Absolute Pres.: 980.0 mbar
Voltage: 13.208 V

005137 - Secondary Air Injection System; Bank 2
P1411 - 002 - Insufficient Flow - MIL ON
Freeze Frame:
Fault Status: 11100010
Fault Priority: 0
Fault Frequency: 5
Reset counter: 255
Mileage: 107015 km
Time Indication: 0

Freeze Frame:
RPM: 947 /min
Load: 31.4 %
Speed: 0.0 km/h
Temperature: 21.0°C
Temperature: 13.0°C
Absolute Pres.: 980.0 mbar
Voltage: 13.081 V

001073 - Warm Up Catalyst; Bank 2
P0431 - 002 - Efficiency Below Threshold - Intermittent
Freeze Frame:
Fault Status: 00100010
Fault Priority: 0
Fault Frequency: 2
Reset counter: 255
Mileage: 107059 km
Time Indication: 0

Freeze Frame:
RPM: 2098 /min
Load: 18.8 %
Speed: 28.0 km/h
Temperature: 41.0°C
Temperature: 12.0°C
Absolute Pres.: 980.0 mbar
Voltage: 13.589 V

[lugars4]

So update, i ran the output tests again and no apparent problems, pump runs and valves actuate ok, no sign of a leak issue.

Decided to run the readiness test in VCDS and both sides passed.....

As the codes are both sides, i am thinking intermittent fault. Relay, solenoid valve, etc?

[lugars4]

So an updae to this:

Still getting the fault codes and engine light every so often.

So far ive confrimed everything i can think of:

- Faulty blower replaced. Confirmed running under VCDS.
- Vacuum leak check performed and tight.
- VCDS of solenoid to actuate the SAI bank valves, confirmed working and valves felt knocking / moving.
- Manually applied hand vacuum pump to each bank valve actuator to open and confirm free flow to exhaust by blowing down the pipe from the blower outlet.
This confirm both valves open under vacuum, hold open without vacuum leak, free flow (blowing by mouth easily), and close sucessfully.

So, in my mind, all of the controls, and system are operational and fault free.

What next?

Its both banks...... So couldnt think it was a faulty lambda sensor? Any ideas?

[r8wut]

hi Mate.. been a while since I've been on here.

Right then, lets get down to brass tacks.

Given the amount of work & effort you've put in recently into the RS - I could help (i've previously had this exact DTC on the vR6) - but can I give you another piece of advice?

MRC Stage 2

You can then kiss goodbye to that annoying Secondary Air pump, associated junk and SAI DTCs forever.

Part of the Stage 2:

Secondary Air Disabled:
Another vacuum controlled solenoid that can cause any issue with any vacuum controlled solenoid(flaps, exhaust flaps, airbox flaps)

Visited MRC few months ago - Stage 2 Tune and .. my god, no regrets..

I should have gone sooner (see my other thread on here)

Might be worth considering.. as now, for a limited time, MRC are offering 30% off their Stage 1+2 Maps!