SAP removal file service — a dedicated ECU calibration that disables Secondary Air Injection monitoring for vehicles where the SAP hardware has been removed or permanently disabled — for track or off-road use, where such modifications are permitted.

SAP Removal – Secondary Air Pump

By deactivating the secondary air injection control and monitoring logic in the ECU, the SAP Removal service prevents pump-related DTCs, MIL lights and readiness failures on engines where the air pump has failed or been removed. All non-SAP engine protection and diagnostic functions remain active.

For a general overview of how secondary air injection works you can refer to the Secondary Air Injection article.

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The Secondary Air Injection system injects fresh air into the exhaust ports or manifold during cold start to speed up catalyst light-off and reduce emissions. It typically includes an air pump, a combination/check valve and one or more solenoids or relays. When components fail or the system is removed, the ECU logs DTCs such as P0410–P0419, triggers a MIL and may alter cold-start behaviour. A dedicated SAP removal calibration disables SAP-specific monitoring and readiness checks so that SAP-related fault codes no longer appear — while closed-loop fuelling, catalyst monitoring and all other emission and safety strategies remain active.

Get your SAP-off file

When is SAP removal recommended?

• After removing or blanking the SAP pump/valve due to failure or a custom exhaust configuration.
• Repeated DTCs such as P0410, P0411, P0412–P0419, or SAP readiness stuck on “Not Complete”.
• Track and off-road vehicles where the SAP system is no longer fitted.
• Cold-start surge or noise linked to SAP activation on tuned engines where the hardware is removed.

Benefits of a correct SAP-off calibration

• SAP-related fault codes no longer appear once the hardware is removed or disconnected.
• The SAP readiness monitor no longer blocks inspection routines on platforms that integrate it.
• Cold-start behaviour stays stable: normal warm-up enrichment, idle control and closed-loop fuelling continue unchanged.
• Only SAP routines are disabled — catalyst monitoring, knock control and temperature protections remain active.

Supported ECU platforms

SAP removal is supported on many petrol ECUs including Bosch, Siemens/Continental, Delphi, Denso and Magneti Marelli. The live coverage checker above is the authoritative list: search your exact ECU model or ID. If your software code is missing, send us your read through the file portal and we will evaluate support. The full service matrix is on the ECU service coverage page.

How the SAP removal calibration is engineered

During a defined cold-start window, the ECU commands the SAP pump and valve based on coolant temperature, ambient temperature and time since start. It expects a distinct lean reaction on the upstream O₂ sensor and, on some platforms, pressure or flow feedback; if the expected pattern is missing or out of range, it sets SAP fault codes and flags the SAP monitor as incomplete. The calibration work follows three steps: assessment (identify the SAP implementation and associated DTC groups on your ECU family), calibration (disable SAP logic and suppress only SAP-related DTCs and readiness tests) and flash & verify (write the modified file and confirm that no SAP faults return and cold-start behaviour remains stable). After the removal, the ECU no longer expects airflow or valve movement during cold start, preventing false lean detection or delayed O₂ transitions — engines with wideband O₂ sensors maintain consistent feedback control without being influenced by the absence of SAP activity.

Compliance, usage and ECU coverage

This calibration is intended only for track and off-road applications where SAP hardware has been removed or disabled and where such modifications are allowed by local regulations. It must not be used to bypass emission-system requirements on public roads. SAP removal does not correct mechanical faults, and all other emission-related components (catalyst, O₂ sensors, EVAP, EGR) must remain functional if still installed. Related services: Exhaust Flap Removal and Cold Start Noise Reduction. Compliance with emission and road-use regulations is the responsibility of the vehicle owner.

Technical background in our knowledge base: OBD system readiness.