Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET2002EXPRESS 1/2 TON VAN V6-4.3L VIN WREPAIR AND DIAGNOSISPOWERTRAIN MANAGEMENTCOMPUTERS AND CONTROL SYSTEMSDESCRIPTION AND OPERATIONEMISSIONS CONTROL SYSTEMSSECONDARY AIR INJECTION (AIR) SYSTEM
2002 Chevrolet Express 1/2 Ton Van V6-4.3L VIN W
Secondary Air Injection (AIR) System
2002 Chevrolet Express 1/2 Ton Van V6-4.3L VIN WSECTION Secondary Air Injection (AIR) System
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.
^ AIR vacuum control solenoid-The AIR vacuum control solenoid controls the AIR shut-off valve. When the secondary air injection 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 valves are vacuum operated. When the secondary air injection system is enabled, vacuum is applied to the valve. The vacuum opens the valve and allows air from the AIR pump to flow to the check valves.
^ Check valves-The check valves prevent back flow of exhaust gases into the secondary air injection system. An AIR pump that had become inoperative and had shown indications of having exhaust gases in the outlet port would indicate check valve failure.
^ 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 (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 HO2S and Short Term 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 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 P0418-A pump relay control circuit problem has been detected.
^ DTC P1415-A bank 1 flow problem has been detected.
^ DTC P1416-A bank 2 flow problem has been detected.
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.
^ AIR vacuum control solenoid-The AIR vacuum control solenoid controls the AIR shut-off valve. When the secondary air injection 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 valves are vacuum operated. When the secondary air injection system is enabled, vacuum is applied to the valve. The vacuum opens the valve and allows air from the AIR pump to flow to the check valves.
^ Check valves-The check valves prevent back flow of exhaust gases into the secondary air injection system. An AIR pump that had become inoperative and had shown indications of having exhaust gases in the outlet port would indicate check valve failure.
^ 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 (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 HO2S and Short Term 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 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 P0418-A pump relay control circuit problem has been detected.
^ DTC P1415-A bank 1 flow problem has been detected.
^ DTC P1416-A bank 2 flow problem has been detected.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.