Secondary air injection Bank 1 & 2
 

With these codes showing up and my engine light on will the 2002 with the 4.4 pass an emission test?

Is there a way to bench test the air pump if I take it out to check it?

Where can I find a factory service manual that I can download?

On the first start in the morning the pump should come on, (#1 in link) so you can tell from under the hood if it is running or not. (sounds like a vacuum cleaner running) Also check the hose from the pump to the valve (#6 in link) to make sure it is still good, then check the vacuum hose to the valve. (valve in #8, you can see the nipple where the vacuum hose goes)

RealOEM.com * BMW E53 X5 4.4i EMISSION CONTROL-AIR PUMP

Ok Thanks. I know what I am doing tomorrow. After moving furniture.

Oops, I meant hose #7, not 6... 6 is the intake hose that goes to the filter, #7 is the one to check. (check them all really)

Ok
The pump is not running.

I took the air filter box out to look at the pump. I noticed a vacuum line that was not connected to anything. Where does this vacuum line connect to? See pic.

I checked all the hoses and they appear to be good with no cracks or breaks.

I checked the vacuum line leading to the valve and sucked on it. I can hear the valve working inside so I am assuming it is working.

If the pump isn't running that's the problem. Now you just need to see if the fuse is blown or the pump is bad... test light/volt meter etc. As for the vacuum hose, what does the other end hook to?

Hooks up to a vacuum operated flap inside the airbox. See pic.
I sucked on the end on the line in the previous picture and it opens and closes.
I want to know where the vacuum line connects to on the outside of the box.

Where is the fuse located for it?

Ok the pump is working now. Connection problem.
The engine light is still on.
Still need to find out where this hose from the air filter box goes.

Ah, the flap... the other end should be hooked to a vacuum supply hose from the intake system, I'll have to remember to look at mine to see exactly where. But on full throttle the flap opens and lets more air in to the box via the opening. If you want you can actually remove that flap and have the less restricted airflow all the time.

As for the check engine light, it doesn't just turn itself off, it needs to be cleared.

I happened to be getting an emission test on my 98 328i and the shop had a 2005 645 in there. Oddly similar looking engine to the 4.4 I have grown to love/hate. The mechanic had a kit from AGA that was not the valve stem seal kit, so we got to chatting. It was for the cleaning of the secondary air injection on the 4.4's. I knew these systems were problematic on the 6-cylinders (mine is a testament to that), but hadn't heard of it on this forum in the year I've been on. So, I found this thread that links to the diagram in the first post (helpful) and I now add the link to this tool in the hopes it helps someone out too.

https://www.agatools.com/tool/n62-secondary-air-cleaner

And here are the videos
https://www.youtube.com/watch?v=CMOjFAKUt30
https://www.youtube.com/watch?v=zMJeXDrrIK8