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01-16-2022, 05:56 PM | #1 |
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DIY: SAP delete
Background
If your Secondary Air Pump went bad or valve is stuck closed you can code it out and leave it in place. But, if one of the Secondary Air Control Valves is stuck open, it causes exhaust leak: It's debatable how bad is this leak, but in any case introducing exhaust gases into intake seems to be suboptimal, so it's time for SAP delete. Level Expert. Each step is not hard, but number of things you'll have to disconnect and reconnect is huge. It's easy to damage engine wiring harness ($900), or some tubing. Tools Required
Preliminary Steps Use this DIY as a guide: https://www.m3post.com/forums/showthread.php?t=735033
Pump Removal
Engine Wiring Harness Removal Engine Wiring Harness needs to be taken out of the way:
Valve Hose Removal Hose was stuck after all these years, so I had some trouble unplugging it. Wiggling it for awhile, I was able to remove it using groove joint pliers to depress latch and piece of rope around tube bend to pull it up. Latch needs to be depressed on the both sides where the plastic ring has some notches just so - pressing it too strong grabs the valve, too light doesn't unlock the latch. Right valve with tubing attached: Left valve with tubing attached: Latch: Removing right valve (bank 1) With wiring out of the way, right valve is trivial to remove. You are not going to be able to see the nuts, so you have to find a nut with your hand, and then remove it using ratchet by feel. (lol)
Right valve removed with gasket still in place Removing left valve (bank 2) Now for the hard part. Left valve has some tubing right on top of it, heat shielding behind it, and steering column on the side.
SAP Relay Removal You don't want loose connector to be powered. Remove SAP relay. This is large orange relay in the fuse box. Result Notice that one valve is just rusted, another one has carbon in it. My guess carbonated valve was leaking. (Although I expected other side since bank 2 was misfiring ) Part 2: Fab and Install I tried to ordered cover plates and intake plug, but one of the cover plates was out of stock. Probably they are not manufactured anymore, so I don't think it's possible to order them anymore. Order parts
Cover plates fabbing Kris cut and welded valves for me to manufacture cover plates (thanks!):
Cover plate install
Now it's the time to put everything back together. (Few hours later...) Dead plug I originally fabbed it using milk jag plastic cap, but then I realized that however unlikely it can be heated too much and melt. So I re-made it using metal lid from a jam jar.
I also had exhaust leak at header-to-midpipe connection. I suspect SAP and exhaust leaks were causing high-rev misfires that ruined few of my track days. I replaced gasket with genuine BMW (third-party leaked right after install), re-did smoke test and did a test drive. All good so far! Now I need to wait for the track day Last edited by vlkvlk; 03-04-2022 at 11:43 PM.. Reason: finish the tale |
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01-16-2022, 10:17 PM | #3 |
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Drives: 2009 E92 M3 Dakar Yellow II
Join Date: Oct 2021
Location: Edmonds, WA
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Is it absolutely necessary to remove the gaskets? Won't you need gaskets for the block off plates?
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01-16-2022, 10:19 PM | #4 |
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Drives: 2009 E92 M3 Dakar Yellow II
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I absolutely despise all SAP systems on any car. In states that have cold winters they're nothing but money printing devices for dealerships and service centers. Great write up. Perhaps follow it up with a video of those components burning in a dumpster fire?
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01-16-2022, 11:49 PM | #5 | ||
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Quote:
Quote:
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01-17-2022, 01:18 AM | #6 | |
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Drives: 2009 E92 M3 Dakar Yellow II
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01-17-2022, 01:21 AM | #7 |
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Drives: 2009 E92 M3 Dakar Yellow II
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Oh, thanks for the link for the endoscope. I've been wanting to pick one up for work.
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03-09-2022, 01:49 PM | #9 |
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For Anyone's Future reference,
I apologize for semi thread jacking, great DYI. I just so happen to source the part numbers for this exact modification. You may have to source some or all through ebay (international seller), Turner and others can get these parts, though currently, some show on back order. Figure i'd attach it here, since it's a great DYI, and easier for future members to find. BMW R19 Plug (for intake, equivalent to BMW Motorsports Plug) P/N 11-61-8-298-015 BMW Secondary Air Cylinder Head Plug (includes bolt mount for heat shield) P/N 11-72-8-297-998 (1-4) P/N 11-72-8-297-999 (5-8) Gasket(s) for block off plates (Qty of 2) 11-72-7-838-389 Optional: BMW E36 Block off plate, thinner, waaaay easier to get a hold of but, doesn't have the bolt hole to mount nearby heatshield. P/N 11-12-1-438-086 Last edited by C-los; 03-09-2022 at 04:55 PM.. Reason: Added Part Numbers |
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03-09-2022, 02:58 PM | #10 | ||
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To add details: I had these exact parts on order with ECS Tuning, but had to cancel and go fab route since it was in backorder status with no projected date. I think it's not really possible to get backing plates at least anymore. I do recommend getting dead plug for airintake - I'm not entirely happy about my DIY plug. This part seems to be easy, but once I started fabbing it I realized there are some limitations: it seats right on top of the engine, so I decided not to use epoxy and plastic to avoid risking it melting. This left me with metal and gasket maker. Should work for now. I ordered proper dead plug internationally, let's see if it will come. |
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03-09-2022, 03:26 PM | #12 |
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Turner and ECS are affiliated, so they show same stock information. It was same situation with my order - one available, one backordered. My guess that single provider in US somewhere has single last plate in stock, get it while you can! 😂
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03-09-2022, 04:41 PM | #13 |
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Yea I have the E36 block off plates already, maybe I'll add them to the parts list up there.. but I'm gonna try my hand at these since they have the bolt hole for the heat shield... So everything is mounted and no rattles.
**edit: added gaskets and E36 block off plates incase people want those for easier access instead Last edited by C-los; 03-09-2022 at 04:55 PM.. Reason: Update: |
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03-10-2022, 02:14 AM | #14 |
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Great DIY! I am having a lot of issues with the SAP lately and was thinking about the delete. I just have one question regards to the coding of the SAP.
I did try to remove SAP before but without SAP it is triggering SES light and set the readiness to fail(code: 27AF - secondary air pump). In my state which has emission testing, I can have one readiness fail but the SES light will prevent me from passing emission at all. Is there any way of coding out the secondary air pump through NCS expert so it will not trigger SES light? May I ask how you deal with the SES light? Thanks. |
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03-10-2022, 07:47 AM | #15 |
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I am unsure about NCS Expert, but I know you can use the MSS60 Binary Modification tool to do it.
Check out the DME Update thread: https://www.m3post.com/forums/showthread.php?t=1783897 It's a one time license fee to modify your factory program, but worth it if you don't already have an 'aftermarket tune'. Now, here's the next bit, do you have cats still? if not, removing the SAP would then give you two readiness monitors failed, 1 for cats, 1 for sap. |
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03-10-2022, 12:09 PM | #16 |
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First and foremost - do a smoke test, if valves are not leaking, it's way easier just to leave them in place. Edit: also it may turn out that header-to-midpipe gaskets are leaking.
My plan is to get a tune, which will code it out, but I haven't done it yet. I don't know if it will help with readiness monitor. In theory you can fake it with putting O2 sensor simulators and emulating MAF SAP sensor, but it's quite involved job. The main problem with SAP is that valves go bad. They tried to fix my SAP two times on warranty, now it's obvious that they had to replace valves, ffks. |
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03-19-2022, 02:44 AM | #17 | |
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03-19-2022, 06:06 PM | #18 | |
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I think used valves are useless - apart from being real hard to install, they will fail in no time. |
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03-19-2022, 09:50 PM | #19 | |
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I pull the fuse, not the relay to save it. BTW, my SAP is tuned out but you'll have a very hard time finding anyone who will do it. I found that I needed the hardware there in order for the monitor to set to "ready." |
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03-31-2022, 05:32 PM | #21 |
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01-06-2023, 12:26 PM | #22 |
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OP, not trying to thread jack but everyone reading this seems to have a similar issue. I’ve been having misfires and burning through o2 sensors like crazy. I’ve replaced every component I can think of apart from the SAP valves. My car is tuned and the SAP is disabled but it’s still not running right. I didn’t want to replace the SAP valves with new ones and run into the same issue later on when they’re not necessary for my application. I have finalized designs for a GT4 block off replica. I was going to have a set CNC machined for myself but if there’s some interest I’d be more than happy to have a few extra sets made up. If anyone is interested shoot me a pm.
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