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M62 8 Cylinder Secondary Air Components Replacement
 
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Pelican Technical Article:

M62 8 Cylinder Secondary Air Components Replacement

Nick Czerula

Time:

2 hours2 hrs

Tab:

$200

Talent:

***

Tools:

Set of sockets, 10mm, flathead screwdriver, plastic gasket scraper

Applicable Models:

BMW X5 Sport Utility (2000-03)

Parts Required:

Secondary air pump, air valve and gasket, hoses

Hot Tip:

Replace any cracked or dry rotted hoses

Performance Gain:

Repair inoperative secondary air pump

Complementary Modification:

Replace engine air filter

The secondary air system is prone to faults that illuminate the check engine light. If you have fault codes for your secondary air, check the operation of the pump. You can test the function of the secondary air components using a BMW scan tool. If you do not have access to one, you can check secondary air pump function when starting the engine. When a cold engine is started, the secondary air pump will run for a calculated amount of time. The check valve is the most common part to fail. In this tech article I will show you how to replace the secondary air pump and secondary air valve.

The secondary air check valve is located under the intake air duct (yellow arrow).
Figure 1

The secondary air check valve is located under the intake air duct (yellow arrow). The secondary air pump is located under the intake air housing (green arrow).

First we have to remove the intake air duct that runs from the throttle housing (yellow arrow) to the mass air flow sensor (green arrow).
Figure 2

First we have to remove the intake air duct that runs from the throttle housing (yellow arrow) to the mass air flow sensor (green arrow).

Working at the fresh air intake, remove the four plastic rivets (green arrows).
Figure 3

Working at the fresh air intake, remove the four plastic rivets (green arrows). Use a pair of pliers (inset) to remove the center rivet. Once all the center rivets have been removed, pull the duct up to detach it from the vehicle.

Then lift the duct up on the left side while detaching it from the duct (green arrow) on the right side.
Figure 4

Then lift the duct up on the left side while detaching it from the duct (green arrow) on the right side.

Working at the mass air flow sensor, loosen the hose clamp using a flathead screwdriver (green arrow).
Figure 5

Working at the mass air flow sensor, loosen the hose clamp using a flathead screwdriver (green arrow).

Working at the throttle housing duct, loosen the hose clamp using a flathead screwdriver (green arrow).
Figure 6

Working at the throttle housing duct, loosen the hose clamp using a flathead screwdriver (green arrow).

Next you will have to rotate the throttle housing duct up toward the left side of the vehicle in the direction of the green arrow.
Figure 7

Next you will have to rotate the throttle housing duct up toward the left side of the vehicle in the direction of the green arrow. This will detach it from the mass air flow sensor. Once detached from the mass air flow sensor, pull the duct off the throttle housing. There are two small hoses you have to disconnect in the following step. Be careful not to damage them during this step.

Working at the bottom of the intake air duct, detach the plastic line by squeezing the release collar (green arrows) while pulling the line off the duct.
Figure 8

Working at the bottom of the intake air duct, detach the plastic line by squeezing the release collar (green arrows) while pulling the line off the duct. Then pull the vacuum hose (yellow arrow) straight off the duct to remove it.

When removing the duct, be sure not to misplace the rubber duct seal (green arrow).
Figure 9

When removing the duct, be sure not to misplace the rubber duct seal (green arrow). The seal will either stay inside the duct or remain attached to the throttle housing.

Secondary air pump check valve:
Secondary air pump check valve: The secondary air pump check valve is located at the right front of the cylinder head.
Figure 10

Secondary air pump check valve: The secondary air pump check valve is located at the right front of the cylinder head. The first step for removing the secondary air valve is to disconnect the vacuum line (green arrow). Pull it straight off to remove it. If the vacuum line is cracked or worn, replace it. This is the vacuum line that runs to the solenoid. If it fails a fault code will be set.

Secondary air pump check valve: Next you have to disconnect the secondary air valve air pipe.
Figure 11

Secondary air pump check valve: Next you have to disconnect the secondary air valve air pipe. Squeeze the release tabs. Then pull the pipe straight off the secondary air valve in the direction of the green arrow to remove it.

Secondary air pump check valve: Next remove the two 10mm nuts (green arrows) from the bottom of the check valve.
Figure 12

Secondary air pump check valve: Next remove the two 10mm nuts (green arrows) from the bottom of the check valve. I find it is easiest to do this using a ratcheting wrench.

Secondary air pump check valve: You can now remove the check valve from the pipe.
Figure 13

Secondary air pump check valve: You can now remove the check valve from the pipe. Once removed, clean the sealing surface (yellow arrow) of the pipe. Install a new secondary air valve with a new gasket and tighten the fasteners. Then install the vacuum line and secondary air pipe. Check the operation of the secondary air components and clear the DME fault codes using a BMW scan tool.

Secondary air pump: 
Secondary air pump: Remove the secondary air inlet hose from the air filter housing by squeezing the release tabs (green arrow) and pulling it straight off.
Figure 14

Secondary air pump: Remove the secondary air inlet hose from the air filter housing by squeezing the release tabs (green arrow) and pulling it straight off.

Secondary air pump: Next you have to remove the intake air housing.
Figure 15

Secondary air pump: Next you have to remove the intake air housing. The ducting was removed earlier. All that is left is the housing. Remove the 10mm fastener (green arrow). Then lift the housing up and lay it aside. I leave the MAF connector on the sensor.

Secondary air pump: Next you have to disconnect the secondary air inlet pipe (green arrow) from the pump.
Figure 16

Secondary air pump: Next you have to disconnect the secondary air inlet pipe (green arrow) from the pump. Pull the hose straight off to remove it.

Secondary air pump: Next you have to disconnect the secondary air pipe from the pump.
Figure 17

Secondary air pump: Next you have to disconnect the secondary air pipe from the pump. Squeeze the release tabs (green arrows). Then pull the pipe straight off the secondary air valve to remove it.

Secondary air pump: Now it is time to unbolt the secondary air pump.
Figure 18

Secondary air pump: Now it is time to unbolt the secondary air pump. You will have to lift it up to disconnect the electrical connector at the bottom. Start by removing the three 10mm fasteners. Two can be accessed easily. One faces the fender, while the other one faces the engine (green arrows). There is one fastener that is tricky, but not impossible. I use a 1/4-inch ratchet, six-inch extension and a 10mm swivel (red arrow). Reach under the air pump (yellow arrow) to loosen this fastener.

Secondary air pump: Lift the secondary air pump and disconnect the electrical connector (green arrows) by squeezing the tabs and pulling is straight off.
Figure 19

Secondary air pump: Lift the secondary air pump and disconnect the electrical connector (green arrows) by squeezing the tabs and pulling is straight off.

Secondary air pump: With the air pump removed, you now have to remove the bracket to swap it over to the new pump.
Figure 20

Secondary air pump: With the air pump removed, you now have to remove the bracket to swap it over to the new pump. Remove the three 10mm nuts (green arrows). To install the new pump, reverse the steps. Be sure to clip the wiring harness to the bracket and double check the hose routing.

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Comments and Suggestions:
eraserhead Comments: Thanks so much. This is the best and most descriptive instructions I've found after way too much looking. Clear, concise, and great pix too.
July 4, 2016
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 

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Page last updated: Fri 12/2/2016 02:39:51 AM