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Secondary air systems are quite simple.....I've had a few stump me but always figured out the problem, i second checking the vacuum resivoir......that's usually the killer.....as if it's got that leak under vacuum (which won't show up under a pressurized smoke test ) it won't have enough vacuum to open the sai valve.......you can stick a hand vacuum pump on it directly, if it won't hold vacuum that's your problem....along with the tech that possibly didn't check this during his multiple diagnosis....but we'll give the benifit of the doubt until you find the problem....