How much does it cost to fix a secondary air injection system?
In most cases, the repair cost for a secondary air injection (SAI) system ranges from about $150 to $1,500, depending on the fault, vehicle model, and labor rates. Simple sensor or valve replacements tend to be on the lower end, while pump failures and damaged lines can push costs higher. The following explains typical costs, what drives them, and how to get an accurate quote.
Costs by component
Prices vary by which part fails and how much labor is needed. Here are common scenarios and their ballpark costs to help you budget.
- Diagnostic/inspection and code read: typically $60–$120, sometimes bundled with the repair if you proceed with the shop.
- Secondary air injection pump replacement: about $350–$700 for parts, plus roughly $100–$350 for labor depending on access and vehicle complexity. Total commonly around $450–$1,100.
- Check valve or air hoses/lines replacement: roughly $50–$250 for parts, plus $60–$150 for labor. Total usually in the $110–$400 range.
- Solenoid or valve replacement (in addition to other components): about $120–$350 for parts, plus $60–$150 labor. Total typically $180–$500.
- Full SAI system overhaul or multiple component failures: often $700–$1,500 or more, depending on vehicle and required parts.
Prices can be higher on luxury or specialty vehicles where parts are expensive or access is difficult. Always request an itemized estimate that separates parts and labor and asks about diagnostic time.
What factors affect price
Several factors influence the final quote beyond the specific bad part. Consider these when evaluating a bid from a shop.
- Vehicle make/model and engine layout, which determine part availability and labor difficulty.
- Regional labor rates and shop pricing policies, which can vary widely.
- Whether the work requires removing other components or special tools, increasing labor time.
- OEM versus aftermarket parts, which can affect both price and warranty.
- Whether the diagnostic is charged separately or included in the repair, and if there are multiple issues.
Getting multiple written estimates can help you compare like-for-like, including parts quality and estimated labor hours.
DIY vs professional repair
SAI systems are part of a vehicle’s emissions control. They interact with the engine’s management software and exhaust system, so professional diagnosis and repair are usually recommended. Improperly tampering with the system can lead to failed emissions tests or further damage. If you’re considering DIY steps, focus on non-mechanical tasks and consult your vehicle’s service manual or a technician for guidance.
Safe, basic checks you can reasonably perform
- Check for obvious signs of cracked hoses or disconnected lines around the engine bay.
- Ask a shop to read your codes to confirm the specific failing component before purchasing parts.
- Avoid attempting to replace pumps or valves unless you have the proper tools and instructions.
For accurate repair work, rely on a qualified technician who can verify the fault, source the correct parts, and verify emissions compliance after repair.
How to get an accurate quote
To obtain a precise estimate, follow these steps and bring relevant information to the shop.
- Record the exact symptom or codes shown by the vehicle’s on-board diagnostics (OBD-II) reader.
- Ask for a written, itemized quote that lists parts, labor hours, and diagnostic time separately.
- Get at least two or three quotes from reputable shops to compare pricing and included services (warranty on parts/labor).
- Clarify whether the quote assumes OEM or aftermarket parts and whether additional fees (disposal, shop supplies) apply.
- Check the shop’s warranty terms for both parts and labor in case the issue recurs.
With a clear, itemized quote, you’ll be better prepared to decide on the repair path and avoid surprise charges at the end.
Summary
Repair costs for a secondary air injection system vary widely but generally fall within a few hundred dollars for basic sensor or valve work and up to $1,500 or more for pumps, hoses, and multi-component repairs. The final price depends on the specific faulty component, vehicle type, and local labor rates. Always seek an itemized estimate, consider multiple quotes, and choose a qualified shop to ensure emissions compliance and a reliable fix.
What are the symptoms of a bad secondary air injection valve?
Potential complaints:
- Secondary air pump does not start after a cold start.
- The engine compartment smells charred.
- Melting traces on the electrical contacts of the secondary air pump.
- P0410 “Malfunction”
How much does it cost to replace a secondary air injection system?
Secondary Air Injection Pump Replacement Cost
However, the average cost to replace the secondary air injection pump often falls within a general range. This range typically spans from $250-$450, with somewhere in the ballpark of $325 serving as a relative average.
Can you drive with a bad secondary air injection?
Though it's better to have the air injection check valve repaired as soon as possible, it is still safe to drive a vehicle even if it's damaged. A faulty air injection system won't significantly affect your vehicle's performance and maneuverability, nor will it compromise your safety while driving.
Is a P0491 code expensive to fix?
Repair costs for a P0491 code vary depending on the root cause but typically range from $400-1200 USD (€350-1100 EUR).
