So, Have followed most of the stickies on this forum since I bought my first D2 this past summer. Now I want to tackle the recently re-broken SAI once and for all.

I am currently throwing a P1412 and a P1415, I had a local ex-land rover tech do some work on the car when I got it, this was on this list, but they have returned. I am also now getting a P0441 code.

The SAI currently has 2 major issues I have identified.

1. the back pipe of my metal secondary air injection pipe on my passenger side has a long crack in it. It makes the car seriously loud, and will blow JBweld out after a couple of days of running. For reference, I am talking about this https://www.roverparts.com/fuel-syst...es/WAP500050G/ (mine has the raise bevels on it though).

I am assuming I should just replace both of the pipes. Anyone know anything I should look out for?

2. My drive rside SAI solenoid on my driver side was NOT mounted to the clip it should have been, and as a result one of the vacum tubes melted. I am unsure about the health of the solenoid itself.

3. Now, for the P0441 code, I have an after market gas cap, and seal looks good. Should step one just be pull and clean the purge valve?

As far as work I am thinking: New Solenoid, new vacuum hoses, new SAI injection pipes. I have already check the pump filter, and that is in good condition.

Would love to hear whether I am missing anything, and if I should look out for anything as I complete the work.

 

Replace the Purge Control Valve with the Hyundai unit and be done with it. I never clean those as there is no real guarantee. The P1412/P1415 Faults are more than likely the vacuum lines going to each SAI stack off the intake. Check the little elbows as well as those can also leak. The OEM lines are hard plastic, but if a piece is melted you can supplement normal vacuum hose, T's, or 90's to make it work. Also if you contact Paul Grant he should be able to hook you up on a used metal pipe, or check Ebay.

 

I had a crack on those secondary air tubes , I used the JBweld heat. Made for exhausts
I used the whole tube just wrap it all the way around the pipe.
Let it cure for min a day before driving
it will stink a bit for a few days but so far it’s holding up
clean the tube area with soap and sand it down with sand paper.
If the crack is to big just squeeze the areas with Chanel locks That metal is very very soft

 

I had the P0441 issue and solved it by adding spring clips to the ends of all the SAI vacuum lines. https://landroverforums.com/forum/di...36/#post727691

 

1. the back pipe of my metal secondary air injection pipe on my passenger side has a long crack in it. It makes the car seriously loud, and will blow JBweld out after a couple of days of running. For reference, I am talking about this https://www.roverparts.com/fuel-syst...es/WAP500050G/ (mine has the raise bevels on it though).
Depending on the area of the crack, you can slip a piece of 3/4" fuel hose or a reinforced silicone hose and clamp it down over the cracked area.

2. My drive rside SAI solenoid on my driver side was NOT mounted to the clip it should have been, and as a result one of the vacum tubes melted. I am unsure about the health of the solenoid itself.
You can replace the vacuum tubes with 3mm ID tubing.

3. Now, for the P0441 code, I have an after market gas cap, and seal looks good. Should step one just be pull and clean the purge valve?
Clean the gas cap threads with a scotchbright pad and definitely replace the purge vale with one of these part numbers...
- #28910-22040 / BMW #11747537612 / #WTV100140A / WTV100150 for 98-05 Hyundai Kia, Sante Fe & Sonata; Bosch part # 0280142310 & 0280142300

 

Appreciate everyone input on this.

I am going to do a mix of the JBweld and hosing clamped over the injection pipe, and see if I can get the crack smaller by compressing the pipe a bit.

I will also see whether I can pick the rest of the parts up today and get this done. After a 180 degree thermostat should be pretty well set (for now).

 

I got some 2.8mm vacuum hose to replace the burnt one, cleared the codes and drove around for the last 2 days. It is not throwing anymore SAI codes. Thanks for the help.

 

Just to update on my fix for the cracked sai pipes coming out of the head. I used the JBweld heat Wrapped it around pipe used the whole tube. Still holding strong after 3 weeks