1 Fault Code found - Secondary Air Injection System - PO411 - 35 NEED HELP

[sambb]

If you go stage 2 you usually get the SAI coded out which means you can get rid of the pump and all its gear. You can remove the combi valve itself from on top of the tower and put a blanking plate there or you can pull out the airbox and a few other things to gain access to where the tower bolts onto the side of the head. The latter makes things a lot neater. Trouble is one of the bolts is directly behind a coolant pipe junction. You don't actually have to loose water. You can slide the spring clip hose clamp out of the way and then pull the coolant hose back and park it just before it springs a leak. With the long end of a ball end allen key (and a tube over the short end) you should then be able to get the bolt off to remove the combi tower and then fit a forge blanking plate or the like to cover over the port. First time around I used an ebay cheapy that claimed to have a viton seal. I was lucky I caught it in time but when I went to steal bits off the old cars engine to transfer onto my new engine, I found that the 'viton' o-ring had mostly melted and was on the brink of being sucked into the exhaust. If it'd gotten thru to the turbine that could have been a drama. I just refit the same plate with the steel gasket off the old tower instead and have had the opportunity to check it a few times and it isn't leaking.
If you find that you do have to pull the hose, leave the coolant bottle cap on and clamp the hose and you shouldn't loose much.

[Polo GTEye N9]

Two choice Al, replace the pump and probably the combi valve too. Or get a tune to fix it. If you're stage 2, I forget, then it's easy for me to arrange that.

Hi Gav, thanks advice and for the offer. I still have the Revo tune on mine that it came with. I knew that you can tune it out but can you sort Revo? Cheers Al

Hi Sam, thanks for your shared SAI experience and a seriously well thought out tutorial on the SAI. Appreciate your efforts to assist. They are not in vain! Well done.

[h100vw]

Won't be able to do anything with the Revo

[Polo GTEye N9]

Won't be able to do anything with the Revo

Hi Gav, you told me that when you were here, just hoping there was a way.

Plan B what ever that is? Will be a considered and well thought out. Doh!

Give me your best offer for tune options, Gav?

Cheers Al

[Stuwey]

see, that's what I expected, so why do people talk about losing water when taking the combi off? where does it come from?

http://www.vwwatercooled.com/forums/f127/sai-n249-removal-44429-4.html#post557120

Combi valve has coolant behind it on the head. It's been a few years and i must admit i don't remember much more than that though!

[Polo GTEye N9]

http://www.vwwatercooled.com/forums/...tml#post557120

Combi valve has coolant behind it on the head. It's been a few years and i must admit i don't remember much more than that though!

G'day Stuwey,

Thanks mate, your original write up for 'SAI and N249 Removal' is a very welcome offering.

What will I need?

330 ohm 10W resistors x 3 of them.
Vac/boost pipe - about 0.5m (from place like Forge)
Combi valve blanking plate (you can get them from Forge but I can make it myself)
Coolant to top up

But is the only way to stop getting a CEL light after removing the 'SAI and N249 Removal' is to have the SAI mapped out?

Euro Tuning website advice is 'NOTE: Be aware that while some codes can be defeated with the resistors the 'secondary airflow code' can only be defeated with software."

Cheers Al

[Polo GTEye N9]

The mighty Gav has sorted out a way to solve this SAI CEL issue permanently, by offering to supply a Blanking Plate and arrange SAI Removal, then a retune coded by a local forum member.

Thanks to everyone who took interest and offered great advice and helpful comments. This is a great forum, the best I am involved with.

But Gav wins out, as he has before.

Al says thanks and is grateful.

[Polo GTEye N9]

Good news,
This morning as arranged, I took the Polo to Lou to do the 'SAI and N249 Removal'.
Lou has done this a few times, he knows what he is doing!
Lou and I went out to a nearby quite location and did a few third gear runs and logged the results which were then sent to Gav who checked them and gave the 'thumbs up'.

Thanks Gav and Lou, 'SAI and N249 Removal' job well done!

But Lou did suggest I fix the cold air intake which was looking pretty tired!

[Polo GTEye N9]

Well after a more kilometers the Polo seems to come on boost a little earlier than Pre 'SAI and N249 Removal'.
Feels good to me.
Thanks Lou and Gav.