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Secondary air intake system problem 960 1996 900 1996

posted by  Vlonjati on  Wed Jan 28 03:31 CST 2004
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I have a very unusual problem in my 1996 960 198k miles.
To make a long story short I get “check engine light”. The code triggered tells me that the secondary air intake system is faulty. The mechanic that I take my Volvo to after reading the code, (I believe it was P0108 I might be wrong), said that that code means the air pump might not work. Well we found out that the pump works just fine. The EGR valve was replaced and the pipes were replaced also. I keep getting the code after driving for a week, or some times two. The wired thing is that in summer time I do not have this problem. I guess it is because the secondary air intake is used only in cold starts at cold temperatures. The car runs reach when I get the light so I reset the code by disconnecting the battery.

Now that I gave some background to my trouble, I was wondering if anyone has any idea to what might be wrong. Keep in mind that everything was replaced with a new part in the system. Also is there a way for the hole that takes this mixture of air and exhaust to the cylinders to get clogged? If it does how do I unclog it? Any ideas?
I know that this problem sound like the one 850’s have code P0410, but the remedy for the 850’s does not help me.

Thank you in advance, Vlonjati







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    Secondary air intake system problem 960 1996 900 1996

    uid 19's pic
    posted by  jbowers on  Wed Jan 28 09:18 CST 2004
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    last visit: Sun Jan 22 13:49 CST 2012
    [RELATED]

    See the posts entitled "Fairly New to the site and Really Need Help!" further down the page. There are many possible solutions.
    --
    '96 965 with 16' wheels at 112K. Had '85 745 Turbo Diesel for 200K.








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      Secondary air intake system problem 960 1996 900 1996

      posted by  Vlonjati on  Thu Jan 29 12:25 CST 2004
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      I went to the Volvo mechanic to get a reading from OBDII and yes it was P04109 with this message, ( P0410 permanent fault, flow to low).
      What does that mean? Any ideas? Is my pump not pumping enough air, or is the pathway of that mixture blocked somehow?
      Guys please help!!!!

      Thank you, Vlonjati








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        Secondary air intake system problem 960 1996 900 1996

        uid 19's pic
        posted by  jbowers on  Fri Jan 30 05:14 CST 2004
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        last visit: Sun Jan 22 13:49 CST 2012
        [RELATED]

        Could be any number of things in that system. You really need the finer breakdown using the Volvo "Diagnostic Trouble Codes", (DTC) which only a volvo scanner can provide to tell you what part of the system is not working.

        There componenets involved are; (1) solenoid run by the ECM that controls the (2) PAIR valve using engine vacuum. The (3)pump controlled by a (4) relay which is turn is controlled by the ECM also. Plus a number of hoses and electrical cables connecting the components together.

        The PAIR valve is located over the exhaust manifold with a 1" or so size hose connecting it to the pump. I assume the pump is obvious? Follow the small vacuum plastic hose from the PAIR valve across the top of the engine to locate the solenoid. Start by checking all the hoses and electrical connectors.

        When my car lit the check engine light with that code, it turned out to be a rotted rubber connector between the PAIR valve and the plastic hose from the solenoid. $1.00 or so part to fix.

        Keep us posted on your findings.
        --
        '96 965 with 16' wheels at 112K. Had '85 745 Turbo Diesel for 200K.








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          Secondary air intake system problem 960 1996 900 1996

          posted by  Vlonjati on  Fri Jan 30 08:53 CST 2004
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          I just got back from my garage atempting to see if any of the rubber conectors between the PAIR valve and the plastic hoses was bad. I checked the rubber conectors and replaced the one that comes right out of the PAIR valve. Doing that the longest plastic hose broke on me fairly easy. I could have been a crack I don't know.

          Well the volvo mechanic reset the code so till I get it again I will wait and see. I might end up taking it in for a diagnostic appointment, and have them tell me what should be done.
          Hopefully what I did today helped though.

          I will keep you posted.

          Vlonjati








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      Secondary air intake system problem 960 1996 900 1996

      posted by  Vlonjati on  Wed Jan 28 18:45 CST 2004
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      Thank you for your for replaying Sir. It looks like from your posting that you think I might have a damaged vacum, air, solonoid, etc...

      Do you think that the "operating conditions are restored to normal" in summer and that is why I do not get this problem?

      Tomorrow I will go at the Volvo dealership, there is a guy there that has been very kind. I will ask him if he can read the code trigered so that I get a confirmation and have a more educated conversation with you guys.

      Thank you, Vlonjati







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