The secondary air injection (AIR) system aids in the reduction of hydrocarbon emissions during a cold start. The system forces fresh filtered air into the exhaust stream in order to accelerate the catalyst operation. The secondary AIR injection pump provides filtered air on demand to the AIR solenoid check valve assembly. The AIR solenoid valve assembly controls the flow of air from the AIR pump to the exhaust manifold. The AIR pump relay supplies the current needed to operate the AIR pump. The AIR solenoid valve assembly has an integral check valve, pressure sensor, and solenoid valve. The pressure sensor monitors the air flow pressure from the AIR pump. The engine control module (ECM) supplies the internal pressure sensor with a 5-volt reference, a low reference, and a signal circuit. The signal circuit provides the ECM with a voltage relative to internal AIR pressure changes.

The AIR diagnostic uses 3 phases to test the AIR system:

1. DTCs P0411 and P2430 run during Phase 1
2. DTCs P2430 and P2440 run during Phase 2
3. DTC P2444 runs during Phase 3

During phase 1, both the AIR pump and the solenoid valve are activated. Normal secondary air function occurs. Expected system pressure is 7-10 kPa above BARO.

During phase 2, only the AIR pump is activated. The solenoid valve is closed. Pressure sensor performance and solenoid valve deactivation are tested. Expected system pressure is approximately 15-20 kPa above BARO.

During phase 3, neither the AIR pump nor the solenoid valve is activated. AIR pump deactivation is tested. Expected system pressure equals BARO.

In all 3 phases, testing is accomplished by comparing the measured pressure against the expected pressure. The ECM can detect faults in the AIR pump, AIR control solenoid valve/pressure sensor assembly, and the exhaust check valve. The pressure sensor can also detect leaks and restrictions in the secondary AIR system plumbing.

DTC P0411 is a Type B DTC.

DTC P0411 is a Type B DTC.

Schematic Reference

Engine Controls Schematics

Connector End View Reference

Component Connector End Views

Description and Operation

Secondary Air Injection System Description

Electrical Information Reference

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

Special Tools

J 36169-HD Heavy Duty Fused Jumper

1. Verify that DTCs P0412, P0418, P2430, P2431, P2432, P2433, P2440 or P2444 are not set.

⇒	If any of the DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle.

2. Ignition ON, command the AIR Pump Relay ON and OFF with a scan tool. The AIR pump should turn ON and OFF.

⇒	If the AIR pump does not turn ON or OFF, refer to Secondary Air Injection Pump Malfunction.

3. Command the AIR Solenoid ON and OFF with a scan tool. The AIR solenoid valve should click with each command.

⇒	If the AIR solenoid valve does not operate as specified, refer to Secondary Air Injection Solenoid Valve Malfunction.

4. Engine running, command the AIR Pump Relay ON with a scan tool while observing the AIR Pressure Sensor parameter. The reading should be 15-20 kPa above the BARO reading.

⇒	If less than the specified range, refer to Secondary Air Injection System Pressure Low.

⇒	If greater than the specified range, refer to Secondary Air Injection System Pressure High.

5. Engine running, command the AIR System ON while observing the AIR Pressure Sensor parameter. The reading should be 7-10 kPa above BARO.

⇒	If less than the specified range, refer to Secondary Air Injection System Pressure Low.

⇒	If greater than the specified range, refer to Secondary Air Injection System Pressure High.

6. Operate the vehicle within the Conditions for Running the DTC to verify the DTC does not reset. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data.

Secondary Air Injection Pump Malfunction

1. Ignition OFF, disconnect the AIR pump relay.
2. Ignition ON, verify that a test lamp does not illuminate between the controlled output circuit terminal 87 and ground.

⇒	If the test lamp illuminates, test the controlled output circuit for a short to voltage.

3. Verify that a test lamp illuminates between the AIR pump relay coil ignition circuit terminal 85 and ground.

⇒	If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the AIR pump relay and/or the AIR solenoid relay.

4. Verify that a test lamp illuminates between the AIR pump relay switch B+ circuit terminal 30 and ground.

⇒	If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal and the B+ circuit fuse is open, test the controlled output circuit for a short to ground.

5. Ignition OFF, disconnect the harness connector at the AIR pump.
6. Test for less than 2 ohms between the AIR pump ground circuit terminal B and ground.

⇒	If greater than the specified range, test the ground circuit for an open/high resistance.

7. Connect the harness connector at the AIR pump.
8. Connect the J 36169-HD wire with a 60A fuse between the AIR pump relay switch B+ circuit terminal 30 and the controlled output circuit terminal 87. Verify the AIR pump is activated.

⇒	If the AIR pump does not activate, test the controlled output circuit for an open/high resistance. If the circuit tests normal, test or replace the AIR pump.

9. Remove the J 36169-HD jumper wire.
10. Connect a test lamp between the AIR pump relay coil ignition circuit terminal 85 and the AIR pump relay control circuit terminal 86.
11. Ignition ON, command the AIR Pump Relay ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states.

⇒	If the test lamp is always ON, test the AIR pump relay control circuit for a short to ground. If the circuit tests normal, replace the ECM.

⇒	If the test lamp is always OFF, test the AIR pump relay control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM.

12. If all circuits test normal, replace the AIR pump relay.

Secondary Air Injection Solenoid Malfunction

1. Ignition OFF, disconnect the AIR solenoid relay.
2. Ignition ON, verify that a test lamp does not illuminate between the controlled output circuit terminal 87 and ground.

⇒	If the test lamp illuminates, test the controlled output circuit for a short to voltage.

3. Verify that a test lamp illuminates between the AIR solenoid relay coil ignition circuit terminal 86 and ground.

⇒	If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the AIR solenoid relay and/or the AIR pump relay.

4. Verify that a test lamp illuminates between the AIR solenoid relay switch B+ circuit terminal 30 and ground.

⇒	If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal and the B+ circuit fuse is open, test the controlled output circuit for a short to ground.

5. Ignition OFF, disconnect the harness connector at the AIR solenoid.
6. Test for less than 2 ohms between the AIR solenoid valve ground circuit terminal 4 and ground.

⇒	If greater than the specified range, test the ground circuit for an open/high resistance.

7. Connect the harness connector at the secondary AIR solenoid.
8. Connect a 15A fused jumper wire between the AIR solenoid relay switch B+ circuit terminal 30 and the controlled output circuit terminal 87. Verify the AIR solenoid valve is activated.

⇒	If the AIR solenoid valve does not activate, test the controlled output circuit for an open/high resistance. If the circuit tests normal, test or replace the AIR solenoid.

9. Remove the 15A fused jumper wire.
10. Connect a test lamp between the AIR solenoid relay coil ignition circuit terminal 86 and the relay coil control circuit terminal 85.
11. Ignition ON, command the AIR Solenoid ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states.

⇒	If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM.

⇒	If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM.

12. If all circuits test normal, replace the AIR solenoid relay.

Secondary Air Injection System Pressure Low

1. Engine running, inspect for exhaust leaks between the AIR solenoid valve and the catalytic converter.

⇒	If an exhaust leak is detected, repair as necessary.

2. Ignition OFF, disconnect the AIR pump relay.
3. Engine running, connect the J 36169-HD with a 60A fuse between the AIR pump relay switch B+ circuit terminal 30 and the controlled output circuit terminal 87. Verify the AIR Pressure Sensor parameter is not 15-20 kPa above BARO.

⇒	If 15-20 kPa above BARO, replace the AIR pump relay.

4. Ignition OFF, remove the J 36169-HD jumper wire and connect the AIR pump relay.
5. Remove the air inlet hose at the AIR pump.
6. Engine running, command the AIR System ON while observing the AIR Pressure Sensor parameter. Verify the reading is not 7-10 kPa above BARO.

⇒	If 7-10 kPa above BARO, the AIR pump inlet hose/pipe assembly is restricted. Remove the restriction or replace the hose/pipe assembly.

7. Ignition OFF, disconnect the hose at the AIR pump outlet.
8. Disconnect the hose at the AIR solenoid valve inlet.
9. Install a length of standard 1 inch I.D. (25.4 mm) hose from the AIR pump outlet to the AIR solenoid valve inlet.
10. Engine running, command the AIR System ON while observing the AIR Pressure Sensor parameter. Verify the reading is not 7-10 kPa above BARO.

⇒	If 7-10 kPa above BARO, test/inspect AIR pump outlet hoses/pipes for leaks or restrictions.

11. Test all AIR pump wiring and connections for less than 2 ohms. If the wiring and connections test normal and the hoses/pipes are OK, replace the AIR pump.

Secondary Air Injection System Pressure High

1. Ignition OFF, remove the AIR solenoid valve.
2. Connect the AIR pump outlet pipe/hose at the AIR solenoid valve.
3. Connect the AIR solenoid valve harness at the AIR solenoid valve.
4. Engine running, command the AIR System ON while observing the AIR Pressure Sensor parameter. The reading should be less than 11 kPa above BARO.

⇒	If greater than the specified value, replace the AIR solenoid valve.

5. Inspect the AIR solenoid valve gaskets for proper alignment. If normal, test/inspect the AIR solenoid valve outlet pipe, exhaust manifold, and cylinder head for a restriction.

1. Install any components or connectors that have been removed or replaced during diagnosis.
2. Perform any adjustment, programming, or setup procedures that are required when a component or module is removed or replaced.
3. Clear the DTCs.
4. Turn OFF the ignition for 90 seconds.
5. Engine running, command the AIR System ON with a scan tool. The AIR Pressure Sensor parameter should be 7-10 kPa above BARO.
6. Engine running, command the AIR pump relay ON with a scan tool. The AIR Pressure Sensor parameter should be 15-20 kPa above BARO.