Hi I have a problem with a 2.0 engine which keeps coming up saying it has a secondary air flow fault. I've had a look at the pipework and this all looks to be ok. I've done actuator tests on the pump, relay and solenoid all of which appear to be working, well at least make noises. I was wondering if anybody else has come across this one? The fault will reoccur about a week after clearing the fault code which is making it hard to solve as it doesn't always do it. Any help would be great.

is it the air injection valve sticking?? it's down the back of the engine on the side of the exhaust manifold and it's an absolute sod to change

Check the vac pipe hasn't come off it.

Thanks for the help I've replaced both vacuum pipes as these were in a sad state but the fault came back after a week. I think it has to be one of 3 things, either the air pump, solenoid or the valve on the manifold. I was hoping someone had seen it before. I'll try and have a look at the valve on the manifold to see if it's sticking.

Check the air pump for leaks especially around the rivets.

I have now tried replacing the secondary air valve on the manifold but the light has come back on after 100 miles. Almost thought I had fixed it but guess not. I'll have to investigate the air pump next I think.

Found that the air pump on mine came apart causing a major air leak. Fixed it with nuts & bolts

I've replaced the valve on the manifold and replaced the vacuum pipes. I have tried a known good secondary air pump and still the fault comes up after about 50 miles of stop start driving. I've tried blanking off the vacuum pipe to the valve but the light has come on again on the way home again after about 50 miles of stop start journeys. Any ideas?

have you tried replacing the coolant sensor, after all the secondary air pump is only supposed to run when the engine is cold

All fixed now with any luck it's now been a week and no sign of a light coming on so fingers crossed