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Old 04-09-2011, 12:21 PM   #1
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Secondary Air Injection System Malfunction

Hi Guys,

My car has thrown the code "P0410 Secondary Air Injection System Malfunction"

The thing is that from what i have read, the secondary pump only works for the first 30 seconds when the car is started. The code came on 30mins into my drive while cruising.

I have not cleared to code so that the dealer can see it on Monday.

Can someone point me in the direction of a HOW TO thread for the relay and pump or any other info i should know about this pump eg Recalls?

Cheers
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Old 04-09-2011, 10:25 PM   #2
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Check out one of my old threads:
http://www.mbworld.org/forums/w211-a...ttle-body.html

This might help.

Regards,
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Old 04-10-2011, 01:44 AM   #3
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check the relay in the boot first, mine had this and the stealer replaced the relay and it hasnt come back since, if that doesnt fix it then it might be the pump
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Old 04-10-2011, 04:38 AM   #4
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Where are the relays in the boot?

I might leave it for the dealer tomorrow as i have one more month of warranty left.

Cheers for the help guys. Its very handy having a scan tool.
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Old 04-10-2011, 05:20 AM   #5
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Well i have just checked my paper work and found out that my waranty has expired.

I went to the car and reset the code and ran it for a while and it has not showed its face again yet........

I opened the boot and puuled the cover off the fuse panel (pic attached) Could someone please tell me what the relays and fuses are for or point me in the direction of a diagram.

Thanks

Click the image to open in full size.
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Old 04-10-2011, 08:31 PM   #6
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Well i drove to work today and the code did not show its face again.
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Old 04-10-2011, 08:52 PM   #7
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I have just found out that none of the relays i posted above are for the secondary air pump.

Could someone please point me into the direction of the relays location?
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Old 04-11-2011, 07:15 AM   #8
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in the spare tyre well on the right hand side, i`ll need to look up which relay but there are only a couple in there, parts department at the dealers should be able to tell you.

...or someone else on here...
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Old 04-11-2011, 09:56 AM   #9
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Thanks mate I'll have a look tomorrow. The engine light still has not shown its face again.
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Old 04-12-2011, 07:44 PM   #10
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Well its back. Driving to work this morning it showed its face. I will be changing out the relay this weekend.
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Old 10-17-2011, 09:19 AM   #11
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Well the car went in to the dealer 12,000km ago to get the parts replaced. All good up until now. 12,000km later and its back. This is pissing me off. Can it really be a software issue?

Anyone had this fixed?
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Old 10-20-2011, 11:19 PM   #12
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Code P0410 Resolved by Dealer

My 2000 ML320 was plagued by this code, and thus a "Check Engine" light for over a year. The fix unfortunately came from the Service Center at my local Benz dealer.

Below is the description of all the things the dealer fixed on my vehicle to clear this code. I'm not very Automobile technical so I would never have tried any of this work myself. Perhaps some of you are.

Service Description:

"Performed Short-test, found codes P0410 and P0442. Checked Actual Values of Secondary Air Injection. Found that intermittently Secondary Air Values went out of spec. Inspected secondary air lines found check valve intermittently sticking. Replaced check valve. Checked actual values of evaporative system and found pressure would not hold. Connected smoke-machine to evaporative system to check for leaks. Found rubber connecting hose at rear of tank cracked. Repaired cracked line. Erased codes. Performed extended test drives, and all is functioning normally."

My "Check Engine" light was coming on at about 110 miles of driving before this work. It has not returned since.

I hope this helps.
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Old 10-20-2011, 11:25 PM   #13
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If your relay is good then it could be your pump. I have a good one if you want it.
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Old 10-21-2011, 08:35 AM   #14
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Thanks Nkosiman. Ill get them to have a look at the rest of the system on my next service.
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Old 11-03-2011, 12:27 AM   #15
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Just a bit of an update. Had the car into MB dealer this morning to double check the firmware. All checked out fine as it had the latest.

Its now booked in in two weeks to try and source the problem. The tech said that it is not the pump as it turns on fine and its not the valve as it is opening as well.
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Old 11-03-2011, 12:38 AM   #16
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Quote:
Originally Posted by Nkosiman View Post
Checked actual values of evaporative system and found pressure would not hold. Connected smoke-machine to evaporative system to check for leaks. Found rubber connecting hose at rear of tank cracked. Repaired cracked line.
This is very interesting, if this is the same hose that is causing all the smell of gas issues with full tanks, I wasn't aware repairing the crack was an option...thought the whole tank had to be replaced. I also thought it was limited to the E class but this was an ML? maybe the tank on the ML is repairable and the E's is not ...
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Old 01-17-2012, 08:00 PM   #17
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Well the saga continues. Its back at the dealer.

A week ago i heard a strange noise comming from the engine bay when driving. I managed to get it to a friends workshop quickly and turned off the car but the noise continued.

I noticed it was coming from the front corner where the secondary air injection pump is located. By this time the a burning electrical smell had started so i pulled the battery lead off to stop the pump. The pump was very hot. After a while i decided to put the lead back on but when i did a big plume of white smoke can from the engine bay (poosibly from the pump siezing). I got under there and pulled the plug on the unit.

The strange thing is a code did not show its face for about a week.

So i dropped the car to the dealer and they are going to get in contact with Merc Australia who will contact Merc Germany to find a solution.
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Old 01-18-2012, 05:47 AM   #18
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The air injection pump seems to be a somewhat common problem on these cars as MANY of the cafax history checks I read for these cars when I was shopping listed that they had been replaced under warranty.
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Old 01-23-2012, 07:33 PM   #19
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Ok I have an update.

Every time the dealer replaced the relay the times before, they were replacing the wrong relay. Apparently my car year/month falls border line with some revisions and that the computer were telling them to change the relay that was in a different location.

So all good now with new pump, relay (thats hidden in the boot) and new fuse (under drivers feet).

Hopefully this never happens again.
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Old 01-23-2012, 10:08 PM   #20
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Please tell me which relay, where? I have had this problem for three months. I have already replaced the air pump, ($437.00, no warranty left). Less than a week later, same code, any help would be appreciated.
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Old 01-24-2012, 12:32 AM   #21
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Im sorry mate i dont know. I think they said behind the boot liner somewhere.
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Old 01-24-2012, 03:43 PM   #22
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Hi - I had same issue with replacement of the parts and relays and it turned out to be also the same blown fuse in drivers side footwell that was causing the CEL to re illuminate

So similar issue after the sec air injection pump and relay/fuses etc were all replaced (that they knew about when the first did it)

This is for a 2004 E55 (RHD Euro)

The CEL came on again after the car had warmed up after about 10 mins driving - same driving pattern as the first time it re-illuminated. Fine when cold then on after 10-15 mins.

Then found that there was another set of fuses that were in the right hand side foot well - inside the car - in a right hand drive on the drivers side up above the pedal area underneath the carpet that were also involved in this circuit.

They had to remove the carpet etc to get to it - there was a fuse related to the air injection system circuit in there that had blown - they replaced this fuse - retested - no code generated - air injection pump working - starting running for 40 seconds or so - shutting down - basically doing exactly what it was supposed to.

It has been fine for several months now so perhaps if you are still getting the CEL on after having the code reset, and pump and relays replaced, perhaps have a look and see if there is a blown fuse -may be worth checking this set of fuses if the guys that have replaced your secondary airpump haven't already. In a LHD car I'm not 100% where it is - it may be in passenger side footwell
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Old 01-24-2012, 06:47 PM   #23
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Hi cbay996,

Yep you are 100% on the money. Just so happens my car is an 04 E55 RHD as well.

When this malfunction happens the pump, fuse and relay must be changed.

Cheers

Adrian
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Old 01-24-2012, 09:06 PM   #24
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Thanks guys for replying, I too have a 2004 e55 but mine of course is LHD. I will look at all those fuses. I do all my own repairs, so I appreciate the information. This is the second time in just 46,000 miles that i have replaced the air injection pump. the first time was at 29021 miles, under warranty, I will let you know what I find out. Thanks.
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Old 11-19-2013, 02:15 PM   #25
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Quote:
Originally Posted by BRH AMG View Post
Thanks guys for replying, I too have a 2004 e55 but mine of course is LHD. I will look at all those fuses. I do all my own repairs, so I appreciate the information. This is the second time in just 46,000 miles that i have replaced the air injection pump. the first time was at 29021 miles, under warranty, I will let you know what I find out. Thanks.
What were you able to find out?

From what i understand, in my 04 LHD (US)- the 40 fuse and the" R" relay next to it in the box under the hood needed replacing after the blown pump is swapped out.

Do you know if there is still additional fuses under the gas pedal on the US version that need to be swapped? Also note: the relay A0025421319 part has been replaced by a newer/updated part # by MB.
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Old 11-19-2013, 02:15 PM
 
 
 
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air, benz, car, code, condary, e55, injection, make, malfunction, mercedes, p0410, pump, read, relay, secondary, system, w211



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