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Secondary Air System

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Howard View Drop Down
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    Posted: 10 Jun 2018 at 9:10pm
My 2002 E39 525i has a problem with the secondary air system.
The secondary air system (SAS) composed of an air pump, a relay, a valve, some electronics and some air tubing is designed to inject air into the exhaust manifold for a couple of minutes when the air temperature is cold.  This ensures that unburnt fuel is burned in the manifold, to reduce emissions and get the cats warm. Lately mine is apparently faulty, and causes some faults when I check it with my Carly Pro ODB11 test kit.
The faults are as follows:
000023 Secondary air pump relay
00003E Secondary Air valve
0000F2 Misfiring Cylinder 5
0000F0 Misfiring Cylinder 3.
The affected plugs were totally sooted up when I changed them, but made no difference to the misfire.
The pump can be in one of two places according to my research. Under the left front wing or bolted on to the engine near the front above the manifold. On my car, I cannot find it, its valve or its relay or any likely looking air tubing to match the works manual. In short,its not there!
 I have spent hours searching the web for a solution, but so far I have not come up with one.
The Bentley manual seems to be lacking any relevent information also.
The car was built late September 2002 and as it's fitted with the later E90 ignition coils, (at the factory) may have a substitute for an SAS system, or a later, undocumented one.
Has anyone got any experince of these items, before I go to the expense of getting a dealer on board?
1988 635csi,
2002 E39 525i, 2001 E38 740i
2003 E39 525i motorsport
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