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Home >> Saturn >> 2003 >> LW200 >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - Self-Diagnostics >> Diagnostic Tests >> DTC P0410: Secondary Air Injection System >> Diagnostic Procedures

Diagnostic Procedures

  1. Did you perform the Diagnostic System Check - Engine Controls? If yes, go to next step. If no, go to DIAGNOSTIC SYSTEM CHECK - ENGINE CONTROLS  under SELF-DIAGNOSTIC SYSTEM.
  2. Turn ignition on, with engine off. Does the Secondary Air Injection (AIR) pump run continuously? If yes, go to next step. If no, go to step  4.
  3. Remove the AIR pump relay. Does the AIR pump run continuously? If yes, go to step  53. If no, go to next step.
  4. Command the AIR pump relay ON and OFF with a scan tool. Does the AIR pump turn ON and OFF when commanded with a scan tool? If yes, go to step  19. If no, go to next step.
  5. Does the WDO/SUNROOF/AIR circuit breaker cycle when the AIR pump relay is commanded ON with a scan tool? If yes, go to step  38. If no, go to step  7.
  6. Turn ignition off. Probe the control circuit of the AIR pump relay at the underhood fuse block with a test light connected to battery voltage. Does the test light illuminate? If yes, go to step  41. If no, go to step  62.
  7. Turn ignition off. Remove the AIR pump relay. Probe the battery positive voltage circuit, switched side, of the AIR pump relay at the underhood fuse block with a test light connected to a good ground. Does the test light illuminate? If yes, go to next step. If no, go to step  34.
  8. Turn ignition on, with engine off. Probe the ignition 1 voltage circuit, coil side, of the AIR pump relay at the underhood fuse block with a test light connected to a good ground. Does the test light illuminate? If yes, go to next step. If no, go to step  15.
  9. Turn the ignition OFF for 15 seconds. Turn ignition on, with engine off. Probe the control circuit of the AIR pump relay at the underhood fuse block with a test light connected to battery voltage. Command the AIR pump relay ON and OFF with a scan tool. Does the test light turn ON and OFF when commanded with a scan tool? If yes, go to next step. If no, go to step  37.
  10. Measure the resistance of the AIR pump relay control circuit with a DVOM. Is the resistance less than 10 ohms? If yes, go to next step. If no, go to step  55.
  11. Install the AIR pump relay. Disconnect the AIR solenoid. Turn ignition on, with the engine off. Command the AIR pump relay ON with a scan tool. Does the AIR pump turn ON? If yes, go to step  65. If no, go to next step.
  12. Probe the AIR solenoid control circuit with a test light connected to a good ground. Does the test light illuminate? If yes, go to step  56. If no, go to next step.
  13. Remove the AIR pump relay. Connect a fused jumper wire between the battery positive voltage circuit, switched side, and the air pump supply voltage circuit at the AIR pump relay connector in the underhood fuse block. Does the AIR pump turn ON? If yes, go to step  44. If no, go to next step.
  14. Disconnect the AIR pump connector. Probe the AIR pump supply voltage circuit with a test light connected to a good ground. Does the test light illuminate? If yes, go to step  16. If no, go to step  52.
  15. Inspect the ignition EIS fuse in the underhood fuse block. Is the ignition EIS fuse open? If yes, go to step  40. If no, go to step  43.
  16. Probe the AIR pump ground circuit at the air pump connector with a test light connected to battery voltage. Does the test light illuminate? If yes, go to next step. If no, go to step  51.
  17. Connect a jumper wire in series between each of the terminals in the AIR pump harness connector and the corresponding terminal at the AIR pump connector. Measure the voltage from the AIR pump supply circuit of the AIR pump connector to the AIR pump supply voltage circuit at the AIR pump relay with a DVOM. Is the voltage drop more than 0.9 volt? If yes, go to step  52. If no, go to next step.
  18. Measure the voltage from the AIR pump ground circuit of the AIR pump connector to a good ground with a DVOM. Is the voltage more than 0.9 volt? If yes, go to step  51. If no, go to step  46.
  19. Start and idle the engine until Closed Loop operation is achieved. Observe the HO2S 1 voltage parameter with a scan tool. Command the AIR pump relay ON with a scan tool. Does the HO2S 1 voltage parameter drop below 75 mV within 10 seconds? If yes, go to DIAGNOSTIC AIDS . If no, go to next step.
  20. Turn ignition off. Disconnect the vacuum line at the AIR shut-off valve. Connect a vacuum pump to the AIR shut-off valve and apply 10 in. Hg of vacuum to the valve. Does the AIR shut-off valve hold vacuum for 30 seconds? If yes, go to next step. If no, go to step  63.
  21. Disconnect the vacuum pump from the AIR shut-off valve. Connect a vacuum gauge to the vacuum line at the AIR shut-off valve. Start and idle the engine. Is the vacuum displayed on gauge more than 0 in. Hg? If yes, go to step  65. If no, go to next step.
  22. Command the AIR pump relay ON and OFF with the scan tool. Does the vacuum displayed on the gauge increase to 10 in. Hg when the scan tool is commanded ON, then decrease to zero in. Hg when commanded OFF? If yes, go to step  31. If no, go to next step.
  23. Remove vacuum gauge from the vacuum line. Connect vacuum line to the AIR shut-off valve. Remove vacuum line from the AIR solenoid outlet port. Ensure vacuum line on the inlet side of the AIR solenoid remains connected. Connect vacuum gauge to the AIR solenoid outlet port. Command the AIR pump relay ON with the scan tool. Does the vacuum on the gauge increase to 10 in. Hg? If yes, go to step  61. If no, go to next step.
  24. Remove vacuum gauge from the AIR solenoid outlet port. Connect vacuum line to AIR solenoid outlet port. Remove vacuum line from the inlet port of the AIR solenoid. Connect a vacuum gauge to vacuum line. Start and idle engine. Does the vacuum on the gauge increase to 10 in. Hg? If yes, go to next step. If no, go to step  42.
  25. Turn ignition off. Disconnect the AIR solenoid connector. Turn ignition on, with engine off. Probe the AIR solenoid control circuit with a test light connected to battery positive. Command the AIR pump relay ON and OFF with the scan tool. Does the test light turn ON and OFF with each command of the scan tool? If yes, go to next step. If no, go to step  29.
  26. Measure the resistance of the AIR solenoid control circuit with a DVOM. Is the resistance less than 10 ohms? If yes, go to next step. If no, go to step  54.
  27. Probe the AIR solenoid voltage supply circuit with a test light connected to a good ground. Command the AIR pump relay ON and OFF with a scan tool. Does the test light turn ON and OFF with each command of the scan tool? If yes, go to next step. If no, go to step  30.
  28. Measure the resistance of the AIR solenoid supply voltage circuit with a DVOM. Is the resistance less than 10 ohms? If yes, go to step  45. If no, go to step  54.
  29. Does the test light remain illuminated? If yes, go to step  35. If no, go to step  36.
  30. Inspect the AIR solenoid fuse. Is the fuse open? If yes, go to step  39. If no, go to step  54.
  31. Remove the vacuum gauge. Connect the vacuum line to the AIR shut-off valve. Remove the AIR pump crossover hose from the AIR shut-off valve. Command the AIR pump relay ON with a scan tool. Is a forceful airflow present at the AIR crossover hose? If yes, go to step  57. If no, go to next step.
  32. Turn OFF the engine. Connect the AIR crossover hose to the AIR shut-off valve. Disconnect the AIR crossover hose at the AIR pump. Turn ignition on, with engine off. Command the AIR pump relay ON with a scan tool. Is a forceful airflow present at the AIR pump outlet? If yes, go to step  60. If no, go to next step.
  33. Inspect for a restriction at the AIR pump inlet hose. Did you find and correct the condition? If yes, go to step  68. If no, go to step  64.
  34. Remove the WDO/SUNROOF/AIR circuit breaker from the underhood fuse block. Test the WDO/SUNROOF/AIR circuit breaker. Is the circuit breaker good? If yes, go to step  58. If no, go to step  59.
  35. Test the AIR solenoid control circuit for a short to ground. Did you find and correct the condition? If yes, go to step  68. If no, go to step  47.
  36. Test the AIR solenoid control circuit for an open or short to voltage. Did you find and correct the condition? If yes, go to step  68. If no, go to step  47.
    37. NOTE: A short to voltage on this circuit will cause the AIR pump to run constantly with the key in the OFF position. Retest the AIR pump operation after repairs.
  37. Test the AIR pump relay control circuit for an open or short to voltage. Did you find and correct the condition? If yes, go to step  67. If no, go to step  47.
  38. Disconnect the AIR pump connector. Command the AIR pump relay ON with a scan tool. Does the WDO/SUNROOF/AIR circuit breaker continue to cycle? If yes, go to step  49. If no, go to step  64.
  39. Test the AIR solenoid supply voltage circuit for a short to voltage. Replace the AIR solenoid fuse as necessary. Did you find and correct the condition? If yes, go to step  68. If no, go to step  48.
    40. NOTE: The ignition 1 voltage circuit is spliced to other components of the vehicle.
  40. Test the ignition 1 voltage circuit for a short to ground. Replace the EIS fuse, as necessary. Did you find and correct the condition? If yes, go to step  68. If no, go to step  58.
  41. Test the AIR pump relay control circuit for a short to ground. Did you find and correct the condition? If yes, go to step  67. If no, go to step  47.
    42. NOTE: Inspect the vacuum check valve for proper installation. The tapered side of the check valve goes towards the vacuum source.
  42. Remove the vacuum line from the engine intake port. Connect a vacuum gauge to the engine intake port. Start and idle the engine. Does the vacuum increase to greater than 10 in. Hg? If yes, go to step  61. If no, go to step  50.
    43. NOTE: The ignition 1 voltage circuit is spliced to other components.
  43. Test the ignition 1 voltage circuit for an open or high resistance. Did you find and correct the condition? If yes, go to step  68. If no, go to step  58.
  44. Test for shorted terminals and for poor connections at the AIR pump relay. Did you find and correct the condition? If yes, go to step  68. If no, go to step  62.
  45. Test for shorted terminals and for poor connections at the AIR solenoid. Did you find and correct the condition? If yes, go to step  68. If no, go to step  65.
  46. Test for shorted terminals and for poor connections at the AIR pump. Did you find and correct the condition? If yes, go to step  68. If no, go to step  64.
  47. Test for shorted terminals and for poor connections at the PCM. Did you find and correct the condition? If yes, go to step  68. If no, go to step  66.
  48. Test the AIR solenoid supply voltage circuit for a short to ground. Replace the AIR solenoid fuse as necessary. Did you find and correct the condition? If yes, go to step  68. If no, problem is intermittent. See INTERMITTENTS in TROUBLE SHOOTING - NO CODES - 2.2L SATURN "L" SERIES article.
  49. Repair short to ground in the AIR pump supply voltage circuit. After repairs, go to step  68.
  50. Repair restriction in the intake port. After repairs, go to step  68.
  51. Repair open or high resistance in the AIR pump ground circuit. After repairs, go to step  68.
  52. Repair open or high resistance in the AIR pump supply voltage circuit. After repairs, go to step  68.
  53. Repair short to voltage in the AIR pump supply voltage circuit. After repairs, go to step  67.
  54. Repair open or high resistance in the AIR solenoid circuit. After repairs, go to step  68.
  55. Repair high resistance in the AIR pump relay control circuit. After repairs, go to step  68.
  56. Repair short to voltage in the AIR solenoid control circuit. After repairs, go to step  67.
    57. CAUTION: Allow the check valve to cool off before proceeding with the next check in order to avoid being burned. Tap on the check valve in order to remove any debris that may be inside the valve.
  57. Repair the restriction or leak in the AIR shut-off valve, AIR shut-off valve outlet hose, AIR exhaust check valve, AIR exhaust check valve outlet pipe, or exhaust manifold. After repairs, go to step  68.
    58. NOTE: Test all spliced circuits to the battery and the ignition 1 voltage circuits for a short to ground before replacing the underhood fuse block.
  58. Replace underhood fuse block. After replacement, go to step  67.
  59. Replace WDO/SUNROOF/AIR circuit breaker. After replacement, go to step  67.
  60. Replace AIR crossover hose. After replacement, go to step  68.
  61. Replace vacuum check valve or vacuum harness assembly. After replacement, go to step  68.
  62. Replace AIR pump relay. After replacement, go to step  67.
  63. Replace AIR shut-off valve. After replacement, go to step  68.
  64. Replace AIR pump. After replacement, go to step  67.
  65. Replace AIR solenoid. After replacement, go to step  68.
  66. Replace PCM. See POWERTRAIN CONTROL MODULE in REMOVAL & INSTALLATION - SATURN "L" SERIES article. Perform PCM relearn procedure. See PCM REPROGRAMMING  under PROGRAMMING. After replacing PCM, go to next step.
  67. Ensure all components are installed and secured. Ensure all connections are connected and secured. Turn ignition on, with engine off. Command the AIR pump relay ON and OFF with a scan tool. Does the AIR pump turn ON and OFF when commanded with a scan tool? If yes, go to next step. If no, go to step  2.
  68. Clear the DTCs with a scan tool. Turn ignition off for 30 seconds. Start the engine. Operate the vehicle within the Conditions for Running the DTC. See CONDITIONS FOR RUNNING DTC . You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records. Did the DTC fail this ignition? If yes, go to step  2. If no, go to next step.
  69. Observe the Capture Info with a scan tool. Are there any DTCs that have not been diagnosed? If yes, go to DIAGNOSTIC TROUBLE CODE DEFINITIONS . If no, system is okay.
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