So I need some help. I purchased a 2001 SC1 with 184,346 miles on it from a used car dealer (trusted, family does a lot if business with them over the years) five months ago as is to commute to and from campus every day. Just as I was getting ready to get it inspected, the secondary air system code popped up. I tested the relay and pump, both are good, replaced the vacuum line (someone glued in the check valve backwards), replaced the EGR valve and O2 sensors, and cleaned out the built up carbon in the exhaust manifold. Each repair was done after the last failed to clear the codes.

The check engine light finally went off and the code was cleared. To test it, I went on a day trip, 200ish miles round trip. The light stayed off for almost a month. It came back on last week and I don't know what else to do. The guy I bought the car from helped me figure out what to do each time but we are both at a loss now.

What do I do now?!? I still need my car to commute back and forth to classes and I don't have a whole lot of money to dump into it. It cuttently has 193,562 miles on it.

 

Please post up the codes that the car threw, so we can get an idea what's going on...

 

P0410

 

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Encyclopedia›OBD II Codes›P0410 - OBD-II Trouble Code (Saturn)
Auto Systems and Repair: P0410 - OBD-II Trouble Code (Saturn)
OBD II Fault Code

OBD II P0410
Fault Code Definition
The Secondary Air System pumps outside fresh air into the Exhaust System during cold engine start up. This additional air helps burn up the highly rich exhaust emissions that are produced when the engine is warming up. The Secondary Air System typically has an Air Pump and some tubes or plumbing to route the air. The system also has a solenoid and Check Valve(s) to control the air flow.

Symptoms

Check Engine Light will illuminate
In many cases, no abnormal symptoms may be noticed
In some cases, the engine may hesitate on acceleration
Common Problems That Trigger the P0410 Code

Defective Air Pump Check Valve(s)
Faulty Air Pump or Air Pump Relay
Faulty air control solenoids or vacuum lines
System may be restricted or plugged with carbon
Common Misdiagnoses

Air Pump Check Valves function, but are slightly restricted
Air Pump is replaced when the relay is the problem
Parts are replaced when the the system is restricted or plugged with carbon
Notes

Many Saturn vehicles set a code P0410 due to a restricted air passage in the cylinder head
Study the Diagnostic Theory section below to learn about the scan tool data that indicates a restricted air passage
Learn more in the Diagnostic/Theory section at the bottom of this article
P0410 Diagnostic theory for Shops and Technicians

When a code P0410 is set, the PCM is not seeing the front oxygen sensor voltage drop sufficiently when the Air Pump is supposed to be adding outside air in to the exhaust system to burn off the excessive HCs and CO that are created during the cold start of an engine. One should test the system with a data streaming scan tool, during a stone cold start up of the engine. Some scan tools provide the Technician methods to test the Secondary Air System or SAS when the vehicle is already warmed up, but this feature is not present on all scan tools.

Cold start the vehicle and watch the front oxygen sensor(s) on the scan tool data stream. After about 5-10 seconds, you should hear the secondary air pump start, it actually sounds like a vacuum cleaner running under the hood. Just as the Air Pump kicks in, the front oxygen sensor(s) voltage should go to less than .125 volts ( 125 millivolts ). If this does not happen, then you have verified a fault condition in the SAS or Secondary Air System.

If you do not hear the Air Pump Motor start, then check the SAS Air Pump and relay.
If you hear the motor, inspect the components that control the Air delivery such as the Check Valve Solenoid, the Check Valve and the rubber hoses, metal piping and passages.
On Saturn vehicles with the metal air pipe that connects to the cylinder head, if the air pump is running but the oxygen sensor voltage does not change, remove the metal air pipe that goes in to the cylinder head and inspect the air passage to see if the passage is plugged or restricted.
Related Items
Secondary Air Injection Error
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P0410 & P0491 Codes
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Haynes shows no Secondary Air Injection System on my vehicle for P0410 Code
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NICE Andy. Thank you