smartcarofamerica.com/threads/p0410-secondary-air-injection-system-malfunction.6826/

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Forum thread: P0410 Secondary Air Injection System Malfunction | Smart Car of America Forum

smartcarofamerica.com/threads/p0410-secondary-air-injection-system-malfunction.6826/ · p. 1 · Applies to: 451

Source: smartcarofamerica.com Topic: Secondary air injection solenoid valve failure Models discussed: 451 Solution status: yes

Problem: P0410 Secondary Air Injection System Malfunction code appearing on early Smart ForTwo 451 models, typically within the first 1000-3000 miles, triggering check engine light (MIL).

Solution: Dealer replacement of the secondary air injection solenoid valve (Bosch part, part number A0025401497). The valve is a small electric component with two vacuum lines in and one out, located below the engine cover retaining clip. Replacement typically takes 30 minutes to 1 hour at authorized Smart centers. Multiple users report successful fixes after dealer service, though one user noted the replacement solenoid had a different part number suggesting design revision.

Key facts: - High failure rate reported: one service tech documented 1-in-9 failure rate among first 90 PDI vehicles - Failure typically occurs between 210-3000 miles on new vehicles - Part is Bosch-manufactured solenoid valve with part number A0025401497 - Vehicle operates normally despite code; no drivability issues reported - Secondary air injection is emissions-related system that operates only during first ~30 seconds after engine start - Replacement solenoid part number differs from original, indicating design or application revision - Multiple Smart centers stock replacement parts due to widespread issue - Can be cleared with ScanGauge II or dealer diagnostic tools after part replacement