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E39 (1997 - 2003)
The BMW 5-Series (E39 chassis) was introduced in the United States as a 1997 model year car and lasted until the 2004 when the E60 chassis was released. The United States saw several variations including the 525i, 528i, 530i and 540i. -- View the E39 Wiki

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  #1  
Old 05-24-2011, 11:09 PM
hokiehigh hokiehigh is offline
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Location: Greenwich, CT
 
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Mein Auto: 2003 540i MSport
540i SES light, secondary air pump related

I recently got a CEL and the Peake code 0F50, 0F51, 0F5D seem to suggest it's related to SAP, I tried to clear it but it will come back within a few days.

I read a lot DIY's about SAP but most are for I-6 engine where the air valve is easy to access, I had a hard time locate the air valve which is hidden under the air intake tube. I finally found time tonight and took out the pump which is also look different than the picture from DIY, see pic below, I can only see a air outlet on the side, there is no air inlet on top. Is it normal?



another shot from top



Also have a question about the black/green hose below, is that vacuum line? It runs into the valve and has a hole on it... what is it for? would that be the reason for the SES light? The bigger hose from pump to the valve is fine.





Any help is greatly appreciated.
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Last edited by hokiehigh; 05-24-2011 at 11:25 PM.
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  #2  
Old 05-25-2011, 12:03 AM
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POof540i POof540i is offline
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Usually what causes the Secondary Air Pump fault code is a stuck control valve (the silver canister in the middle of the pic). If you're going to throw parts at it, start with that first. Do not buy a new pump until you rule out the valve first. Of course I would probably start by replacing that green hose first, then the valve. If you think you may need a pump, I have a brand new I'm looking to sell if you're interested.

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  #3  
Old 05-25-2011, 12:33 AM
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bluebee bluebee is offline
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This thread has nice pictures and covers the 540 so I'll add it to the bestlinks:

- Where is the secondary air pump (1) & how to diagnose a secondary air system failure (1) & what are the most common two failure modes (1) (2) & a DIY to perform SAS troubleshooting with the infamous fuse #107 (1) (2) & what to do when the SAP (1) clogs or freezes (1) or the diverter valve clogs (1), taking out the S.A.S. (1) (2) (3) (4) (5) (6) (7) & a S.A.P. replacement DIY (1) & a Pierburg air pump maintenance (1) & rebuild DIY (1) (2) & well thought out SAS/SAP simulation testing (1) & repair strategies (1).
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  #4  
Old 05-25-2011, 06:31 AM
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Fudman Fudman is online now
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Mein Auto: '02 530i Sport auto
I can't see your pictures but the small hose that attaches to the check valve provides vacuum that actuates the valve. If there is a hole in the hose, replace that section of the vacuum hose first. That should restore check valve function. Clear the code and start your car when it is stone cold. The SAP should fire up and run for 1-2 minutes. It should then shut off. If you don't hear the pump, then you'll need to replace the pump and the valve (the usual cause for a failed pump). If pump operates properly and you are still getting the code, the problem is the associated with the check valve. If you replace the vacuum hose, clear the code and it returns again, then you need to replace the valve.
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  #5  
Old 05-25-2011, 11:48 AM
hokiehigh hokiehigh is offline
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Mein Auto: 2003 540i MSport
Thanks for the quick reply, I'll following you guys' suggestion start with the vaccum hose/ valve. The pump maybe okay, there is no water inside, and at least some times I can hear it on. Losing vaccum must cause the valve to stay shut instead of stay open

POof, thanks for the offer, I'll keep that in mind if I need a pump.
BLue, thanks for the detailed reference, as always.
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  #6  
Old 06-07-2011, 02:57 PM
hokiehigh hokiehigh is offline
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Mein Auto: 2003 540i MSport
update:

I cut off the broken section of the hose (right at where it connects to the valve) and reconnected it, cleared the SES light and it hasn't come back for the past almost two weeks. I'll order a new hose to replace the old one soon.

air pump works just fine.
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  #7  
Old 06-07-2011, 05:57 PM
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POof540i POof540i is offline
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Dang it! I was hoping to sell you my pump. Oops, I meant I'm glad it was just the hose.
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  #8  
Old 12-06-2012, 09:48 PM
Bennt771 Bennt771 is offline
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Would like to say thanks as well. My hose was split. Check valve to valve.

Woops, spoke to soon. Did not fix.. will have to dig deeper

Last edited by Bennt771; 12-10-2012 at 01:53 PM.
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  #9  
Old 12-14-2012, 07:13 PM
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540iman 540iman is offline
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Mein Auto: 2002 540i sport
An Audi A2 pump 2002-2004 will work, but requires possibly a new connector. Audi replacement pumps are under $110 on Amazon. BMW wants $300 almost. You pump sucks air from bottom through a foam filter. In future, just check cacuum at valve with your finger and check pump flow at valve hose. Needs to be STRONG and never run more than about 3 minutes or it will burn up.
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