2002 grand prix gt p0410 code :(

I have a 2002 Grand Prix GT with a 3.8 that has 59000 miles on it. I just bought this car last year, and about 2 months later the check engine light came on. Brought it to a couple of mechanics and they found the P0410 code "Secondary Air Injection system malfunction", but couldn't figure out the problem. So I took it to the local dealership.....about 8 times. They would replace one part, then the light would come back on.....replace another and it would come back on...and so on. So they ended up replacing pretty much the entire system. And a few months after it was all said and done and paid for (over $900, but the person I bought it from took care of it thank god) the light comes back on for a little while, and eventually goes off. For the past 4 months it has been on, and I brought it to Autozone and the SAME code came up! I brought it to my regular mechanic to take a look, and he found carbon and water buildup in the system. So he cleaned the lower part of the unit, but he said he couldn't get to the upper part, the dealership is the only place that has the part to get in there. So......back to the dealership I go. :banghead: They said there was no problems with the parts they had installed (because I did get a warranty with those), so they finished cleaning the buildup and condensation out, and said that the car ran 4 self tests and passed all of them. So I drive it 114 miles and the light came back on grrrrrrr! I need to get the car inspected, I'm almost 2 months past. Is there something else that can be done???? The mechanics at the dealership didn't really tell me much or seem to know too much on how to take care of the problem. I don't mind paying to have the system cleaned once a year, but if they replaced so many parts, I shouldn't have any more problems with the same system!!! I love the car and just want the problem taken care of. Any suggestions would be greatly appreciated. I don't have the specifics of the parts replaced right now, but I will repost what they were when I have the receipts handy.

Hope this helps.

I'd be sure they looked at the service bulletin:

#04-06-04-037: Check Engine Light On, DTC P0410 Set, Water in AIR Pump (Replace AIR Pump, Install New Hose and Shield) - (May 27, 2004)


Subject: Check Engine Light On, DTC P0410 Set, Water in AIR Pump (Replace AIR Pump, Install New Hose and Shield)


Models: 2000-2002 Buick Regal

2000-2002 Chevrolet Impala, Monte Carlo

2000-2002 Oldsmobile Intrigue

2000-2002 Pontiac Grand Prix

with 3.5L or 3.8L Engine (VINs H, K - RPOs LX5, L36)




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Condition
Some owners may comment on the check engine light being illuminated. Upon investigation, the technician may find a DTC P0410 indicating that there is a concern in the secondary air injection system. When removing the air pump, the technician may also note evidence of water intrusion in the secondary air injection pump.

Cause
Water may have collected in the AIR pump and frozen or corroded the pump.

Correction
Replace the Secondary Air Injection Pump and install a new hose, shield and cleaner using the following procedure:

Some more info:
Secondary Air Injection System Description
The secondary air injection (AIR) system helps reduce exhaust emissions. The system forces fresh filtered air into the exhaust stream in order to accelerate catalyst operation.

The system includes the following:

• AIR pump--The AIR pump supplies filtered air through the secondary air injection system into the exhaust stream. The control module provides ground for the pump relay. Battery voltage is then applied to the pump. The filter is the only serviceable part of the pump.

• AIR vacuum control solenoid--The AIR vacuum control solenoid controls the AIR shut-off valve. When the AIR system is enabled, the control module provides a ground to the solenoid. Enabling the solenoid, allows engine vacuum to be applied to the AIR shut-off valve.

• AIR shut-off valve--The AIR shut-off valve is vacuum operated. When the AIR system is enabled, vacuum is applied to the valve.

• Check valves--The check valves prevent back flow of exhaust gases into the AIR system.

• Plumbing--The plumbing carries the air from the pump to the exhaust stream. The plumbing includes the hoses, pipes and clamps. The plumbing can be tested for leaks using a soapy water solution. With the AIR pump running, bubbles will form if a leak exists.

Results of Incorrect Operation
If no air, or oxygen, flow enters the exhaust stream, the start up emission levels will rise. The control module can detect a system flow problem using the pre-catalyst heated oxygen sensor (HO2S) and short term fuel trim (FT). If a system flow problem is present the HO2S voltage will not indicate an expected lean condition, short term FT will not increase and a DTC will set.

If incorrect voltage is present on the vacuum control solenoid or the pump relay control circuits the device will not operate. This will be detected by the control module and a diagnostic trouble code (DTC) will set.

The following DTCs can set if a secondary air injection fault is detected:

• DTC P0410--A system flow problem has been detected.

• DTC P0412--A vacuum control solenoid control circuit problem has been detected.

• DTC P0418-- A pump relay control circuit problem has been detected.

I have a 2002 Grand Prix GT with a 3.8 that has 59000 miles on it... found the P0410 code "Secondary Air Injection system malfunction"
My 2001 3.8 GT with 47,895 miles (in July of 2005) got the same code while the car was driving poorly and lack of accerleration... At the end, Pontiac dealership determined and replaced my clogged catalytic convertor. Would not be a bad idea to check for a bad cat. convertor as air pump is closely linked to it -- both are parts of same exhust emission control system.

The car actually drives great - there's no difference in driving when the light is on or off, But i'll have my mechanic check for that just to see. Thanks!

Yes, they did have that bulletin & they replaced the following: Hose Assembly, Shield & Pump. This was after they found water intrusion in the air pump. Last week when I went, they said there was nothing wrong with the parts they installed, and they said "the vehicle ran a self test, and has passed last 4 tests, no problem found at the current time". So I just can't understand why I'm still having this problem!!!!!!!!!! Should I try to bring it to a different dealership?