Pro Spanner Wielder
How to remove the Secondary Air Injection Pump fitted to X14/X16XE sport engines.
- 13mm socket
- Ratchet Extension
- Hose Clip Remover Tool (or large pliers)
- Large Hammer
- 20mins max
- Nothing providing you have the tools.
Step 1 - Locate the SAI Pump in the engine bay of your X14XE or X16XE Sport. It's on the right, in front of the battery, behind the power steering reservoir.
Step 2 - Note where the output feed from the pump goes to, the silver turret looking thing is a valve into the exhaust manifold. This is where we will disconnect from, the valve remains untouched (unless you replace your exhaust manifold with a 4-2-1, then it disappears).
Step 3 - Behind the run of vacuum lines you'll see the looms sensor/wires that plug into a block on the pump and come out the other side with the power wires to run the pump. This is how the ECU controls whether the pump is on or off.
Unplug the ECU sensor from the block on top of the pump as shown, tuck the sensor plug out the way for now.
Step 4 - Locate the two 13mm bolts holding the pumps mounting braket into the engine bay. They are on the right hand side of the pump, at the bottom. You will need to use an extension on your ratchet for these.
The rear of the two bolts on mine was rusted and corroded extremely tight due to a previous battery acid leak. After sheering a 3/8" drive extension. I cracked out the 1/2" drive extension and breaker bar. It didn't stand a chance, sodding thing. Once cracked off, resume play with 3/8" drive socket.
You'll be left with this. In my case, removing the rear nut was only half the solution, as the battery acid had corroded the bolt body to the mounting bracket, and the base that the bracket was bolted to... This is where the hammer comes in... Whack the crap out of the mounting bracket until the corrosion breaks up and the bracket comes free.
Step 5 - Using your vauxhall approved hose clip removing tool (big pliers) pinch together the hose clip holding the pumps output pipe to the valve on the exhaust manifold. With it squeezed, slide the clip up along the hose to clear the valve, then slide the hose off of the valve barb.
You'll be left with this. Do not unplug the vacuum hose that enters this valve.
Step 6 - Lift out the pump and its mounting bracket, as long as you've removed the sensor plug and the pump output hose from the manifold valve then it should come free. You'll have a big empty space that looks like this now.
And this is what you've taken out, the pump at the top, the output hose on the left, and the round part on the right is the pumps intake filter. In this pic i've taken each part off of the pump, this isnt necessary, but makes it easier when taking it out. If you want to do this, just use the pliers to undo the 2 extra hose clips.
And voila! All done, you may want to take your battery off for a few hours to reset the ecu so it can learn of the change to its fuelling that you're going to create. Mine for example, turned over, fired, and then died on the first turn of the key. Started up fine the second turn and has been fine since. Pretty certain that was the ecu throwing a fit that it wasnt there, and then learning how to fuel the car at startup without the pump.
Job done. Dave