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06 Milan P0410 P0491 P2258 AIR system problems

30K views 3 replies 3 participants last post by  ahanix1989 
#1 · (Edited)
Had these codes for a long time but want to sell the car so its time to address. Figured I'd post up some of the things I discovered for others.

I checked the manual and found the system consists of a few things. Valve, pump, hoses, vacuum line, a few fuses, and a relay. I figured they would all die with the same problem but when I googled looking for the most common issue, I basicly found a bunch of people saying the dealer swaps the pump or valve and then they have to go back for the other a week later. Seems the dealer charges in excess of 1000 bucks for this. What a crime if you ask me. to replace both parts would take maybe an hour for an amature.

I havent actually fixed this yet but I'll show you what I have found thus far and I have a pump on order...I'll let you know if it fixes it later this week.

First thing I did was a quick visual inspection, checked the fuses and tested the relay. (testing is easy with some scrap wire and a 12v light bulb...but its really cheap so if your worried about testing...just replace it.) Everything seemed tight and intact. Fuses and relay were ok.

Next thing was I tried to test the pump. I consulted this wiring diagram and supplied 12 to the connector..I figured whats the worst thing that could happen if its bad anyways..haha



I jammed some wires into the plug...(This pic is from later after I removed the pump...but you get the idea) Positive on the left...(The plug from the car has gray and black...both with yellow stripes but on the pump side its old fasion red and black)


added some power


...And nothing happened.

So I dont know how effective this test is but I assumed its the pump and started moving that direction.

When I removed the pump, about a cup to a pint of water came out. so I think I'm on the right track. I decided to take apart the pump so I could see if I could figure out a way to fix it...(Yeah...the part is on order now..lol.) Since that didnt pan out...I'll post the pics anyways so you can see what it looks like inside.

I had no room so i setup my testing right underneath my car..lol


Here is the pump with the bracket removed


Bolts were seized on so I drilled the top and knocked off the head with a chizel


Its pretty east to pry apart


What a mess! I still cant figure out how water gets in this thing. I was suprised to find it still spun freely


Continuing on to the back...


Just as messy on this side



At this point, I added power directly to the motor and it didnt do anything so I'd say my first test was valid.

I have a new part on order from rockauto...cx2032 It comes with the pump, bracket, and hoses for the same price as cx2036 which is pump only. Paid just under 150 shipped.

I let you know what happens when I install the part next week.
 
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#2 ·
Update on this.

Replaced the pump and it solved the p2258 code but the other two came right back. (This also solved my wrench light btw)

I went to replace the valve and found its on national back order to mid march. This was unacceptable so I went to a U-pull it junk yard and found the exact same valve part on a few years of focus's. (They didnt have any fusions or Milans)

Picked up two of them for 20 bucks and headed home. I took all the hoses off of it and then yanked the two screws out to see what I could see. I found that I could apply a little vaccum to it (I sucked on it and put my finger over the hole...lol) and could hear the valve make noise. however, the valve didnt seem to open. I then blew on the valve through the intake part and it flew right open. I would seem that the vacuum doesnt open the valve inself, rather it only removes what holds the valve shut.

I then tested the part of my car and could not get that valve open in the same manner. Long story short, It worked. no more codes.

One other thing was the little electrical solenoid...I was able to test that with 12v. (Just some more info for future searchers)

Good luck.
 
#4 ·
I don't know much about these systems. EBSCOhost is showing that removing a Secondary Air Pump is pretty straightforward -- remove the underbody shield, disconnect harnesses, disconnect air hoses...

Secondary Air Pump
Removal and Installation

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.
If equipped, remove the 7 screws and the underbody cover.
Disconnect the secondary air pump electrical connector.
If equipped, release the 3 wire harness retainers from the secondary air pump hoses.
Release the clamp and remove the secondary air pump hose from the air inlet duct.
Release the clamp and remove the secondary air pump hose from the secondary air valve.
NOTE: Crimp style clamps retain the hoses to the secondary air pump, therefore the pump and hoses are removed as an assembly.
Remove the 3 bolts and the secondary air pump and hoses as an assembly.
To install, tighten to 30 Nm (22 lb-ft).
To install, reverse the removal procedure.
 
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