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Old 12-25-2015, 10:32 AM
TimFreeh TimFreeh is offline
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Join Date: Aug 2001
Location: Milford, DE
Posts: 1,558
How did your indie verify that the ports in the cylinder head are clear? If the pump and switchover gear are working correctly there aren't too many other possibilities....

I've fought this problem before and in my case the air injection ports in the cylinder head were plugged, many sources said that cylinder head removal with a hot-tank soak was the only way to clear the ports. I was able to clear the ports with a combination of solvents, reaming with EGR snakes, compressed air and time. There are ports to all 3 cylinders on each bank but I've found that the system will work well enough to evade the P0410 if you can just get one port clear.

The Star SDS and some other high-end scanner tools have a test procedure that will activate the switchover gear and energize the air-pump while also displaying the O2 sensor voltages. This takes a lot of the guesswork out of diagnosis and troubleshooting.
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