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Secondary Air Pump Replacement
 
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Pelican Technical Article:

Secondary Air Pump Replacement

Jared Fenton

Time:

1 hour1 hr

Tab:

$250 to $600

Talent:

**

Tools:

T40 Torx driver, small flat head screwdriver

Applicable Models:

Porsche 955 Cayenne S (2003-08)
Porsche 955 Cayenne Turbo (2003-08)

Parts Required:

Secondary Air Pumps

Hot Tip:

Walk the air hoses off the pumps with a small screwdriver

Performance Gain:

Better running engine

Complementary Modification:

Replace torque strut

The secondary or auxiliary air pump is part of the emission system and is used to inject fresh air behind the exhaust valves during the engine warm up. The air produces an oxygen rich environment that assists in after burning and helps the engine run cleaner during warm-up.

If you suspect a problem with the secondary air pumps, start the car when cold and open the hood. You should be able to hear the pumps running. If not, use a diagnostic scanner to check the vehicle's fault codes. A P0491 or P0492 would be the most common codes and would indicate a problem.

You'll also need to remove the top rear engine cover for access to the mounting screws. See our article on removing engine covers for more information.

Both Left and Right Sides - Begin by removing the six T40 Torx screws (green arrows) that hold the secondary air pumps to the brackets mounted above the cylinder heads.
Figure 1

Both Left and Right Sides - Begin by removing the six T40 Torx screws (green arrows) that hold the secondary air pumps to the brackets mounted above the cylinder heads. Once the bolts are removed, pull the vacuum lines (yellow arrows) off each air pump. You may find that the hoses are stuck in place. In this case, it may be easier to leave the pump bolted to the bracket and use a small flat head screwdriver to carefully walk the hoses off.

Both Left and Right Sides: Carefully pull the electrical connection up and off the mounting bracket (green arrow).
Figure 2

Both Left and Right Sides: Carefully pull the electrical connection up and off the mounting bracket (green arrow). Once removed, press the tab on the connector (yellow arrow) and pull the harness apart. You can now install the new pumps in reverse order.

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Comments and Suggestions:
noel Comments: nick..question about secondary air pump p0492..what side is p0492..passenger side or driver side
December 6, 2016
Mkiany Comments: Hi;
I have a Porsche Cayenne S 2004 with 88k miles,and I have had problem with Secondary air pump from 2 years ago .It happens mostly when the whether get cold.The check engine gets on and diagnostic shows P0492.I did replace pump one years ago and many time fuse.Now again same problem I think I have to change relay but I do not know where is it?
October 8, 2016
  Followup from the Pelican Staff: before replacing anything, is the pump running when the engine is started? The issue may be a faulty check valve, allowing moisture into the pump. - Nick at Pelican Parts  
Steve Comments: I got the P0491 code and upon inspection of the air pump found the blades of the pumps fan to be in pieces. Some of the pieces were blown up into the outlet tube. Should I try to replace the secondary air valve as well? Could it have been harmed by the small pieces of fan blade?
May 25, 2016
  Followup from the Pelican Staff: I would at the minimum remove and check if it is clean and free of debris. - Nick at Pelican Parts  
Vin Comments: I replaced the bank 2 fuse and a few minutes later the fuse blew again. I'm going to remove the pump and measure resistance to see if it's shorted and needs to be replaced. You agree with this?
October 21, 2015
  Followup from the Pelican Staff: Pumps do fail often, and fuses fail when they do. So it could be your issue. - Nick at Pelican Parts  
Jbob Comments: Will a defective secondary air pump cause the vehicle not to start?
September 17, 2015
  Followup from the Pelican Staff: no. - Nick at Pelican Parts  
Dylan Comments: Hey Nick thanks for the advice.. Is pump 1 located passenger side? Cheers Dylan
April 4, 2015
  Followup from the Pelican Staff: I believe so, repair information states right at fuel pump 1. To confirm, remove a fuse and check that the right pump doesn't have power. - Nick at Pelican Parts  
Dylan Comments: Also what is easiest or most obvious way to know which pump is defective? Thanks Dylan
April 1, 2015
  Followup from the Pelican Staff: Locate each pump, activate the pump using a scan tool, check for air volume. - Nick at Pelican Parts  
Dylan Comments: Hi I have 04 cayenne turbo..
I have cel, blown fuse 3 and whining from one or both? of the pumps upon cold startup. Otherwise runs fine. Started this winter which was coldest here In Virginia beach . Should I just replace the pumps? Are they different right vs left? fuse 4 is fine so I assume one pump is working fine.Many thanks. Cheers Dylan
April 1, 2015
  Followup from the Pelican Staff: Fuse 4 is for pump 2. Pump 1 sounds like it is your bad one. - Nick at Pelican Parts  
Max_O Comments: I think he means that the air pump will not start, not the vehicle. It could be the relay or bad pump.
January 11, 2015
  Followup from the Pelican Staff: I got that. Thanks. - Nick at Pelican Parts  
Jinx Comments: Nick, as it turned out it was the pump relay that was bad. Jinx
December 9, 2014
  Followup from the Pelican Staff: Thanks for the follow up. - Nick at Pelican Parts  
Jinx Comments: Codes are PO491-492. The porsche starts and runs fine. Check engine light is on. Indepent mechanic stated he could not hear the air pump start.
And would have to check the air system component by component
My question is what starts the air pump?
December 5, 2014
  Followup from the Pelican Staff: The DME turns the air pump on. - Nick at Pelican Parts  
Jinx Comments: 2003 boxster. Codes PO491 PO492. Cannot hear the air pump. What would cause it not to start, and where do I go from here,
December 4, 2014
  Followup from the Pelican Staff: No, the air pump will not cause a not start.

I can't help without knowing what is missing from the system when you are trying to start it. When your engine doesn’t start you’ll want to check the basics. Check spark, fuel injector pulse and fuel pressure, volume and quality. Are there any fault codes? Once you figure out what is missing, it will be easier to diagnose.
- Nick at Pelican Parts
 

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