Parts of Secondary Air Injection (AIR) system (vehicles with engine code BDF), removing and installing: Notes

WARNING: This page does not describe the selected car, but rather 14 other vehicles, including the 2005 Volkswagen GTI, 2004 Volkswagen R32, 2004 Volkswagen Jetta, 2004 Volkswagen GTI, and 2003 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Secondary Air System Components (Vehicles With Engine Code BDF)

GW00000940

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secondary Air Injection (AIR) Pump Relay -J299-*. See Relay position assignment in protective housing (engine compartment, left)

1 - Intake manifold

2 - Vacuum actuator

for intake manifold change-over

3 - To intake manifold

Refer to Intake manifold (vehicles with engine code BDF), disassembling and assembling , item 10

4 - To fuel pressure regulator

Refer to Fuel rail (vehicles with engine code BDF), disassembling and assembling , item 11

5 - Combination valve

checking. Refer to Combination valve, checking

6 - Gasket

replace

7 - Air channel

in cylinder head

8 - 8 Nm

9 - Ground (GND) connection

Check for secure fitting

10 - Connecting piece

for combination valve and coolant hose

11 - 5 Nm

12 - Pressure hose

Check for secure fitting
To disengage, squeeze together at front

13 - O-ring

replace if damaged

14 - Connecting piece

15 - Air filter

Clean if soiled

16 - Screw clip

17 - Bracket

For Secondary Air Injection (AIR) pump motor
Secured to oil pan and to cylinder block

18 - 20 Nm

19 - Rubber bearing

20 - Secondary Air Injection (AIR) Pump Motor -V101-*

checking. Refer to Secondary Air Injection (AIR) pump motor, checking

21 - Intake hose

Check for secure fitting
To disengage, squeeze together at front

22 - Connector

black, 2-pin
For Intake Manifold Change-Over Valve
before disconnecting, mark allocation to component

23 - Connector

black, 2-pin
for Secondary Air Injection (AIR) solenoid valve
before disconnecting, mark allocation to component

24 - Intake Manifold Change-Over Valve -N156-*

checking. Refer to Intake manifold change-over valve, checking

25 - Secondary Air Injection (AIR) Solenoid Valve -N112-*

checking. Refer to Secondary Air Injection (AIR) valve, checking

26 - Vacuum reservoir

for intake manifold change-over
For Secondary Air Injection (AIR) system

27 - Check-valve

Note installation position
White connector points to Secondary Air Injection (AIR) Solenoid Valve -N112-/Intake Manifold Change-Over Valve -N156-

28 - Connector

black, 2-pin
For Secondary Air Injection (AIR) pump motor