Parts of Secondary Air Injection (AIR) system (vehicles with engine code BJS), 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 Injection System Components, Assembly Overview (Vehicles With Engine Code BJS)

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 BJS), disassembling and assembling , item 7

4 - To fuel pressure regulator

Refer to Fuel rail (vehicles with engine code BJS), disassembling and assembling , item 9

5 - Combination valve

checking. Refer to Combination valve, checking

6 - Gasket

replace

7 - Air channel

in cylinder head

8 - 10 Nm

9 - Connecting piece

for combination valve and coolant hose

10 - 5 Nm

11 - Pressure hose

Check for secure fitting
To disengage, squeeze together at front

12 - O-ring

replace if damaged

13 - Connecting piece

14 - Bracket

For Secondary Air Injection (AIR) pump motor
With oil pan support

15 - 20 Nm

16 - Connector

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

17 - Rubber bearing

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

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

19 - Air filter

Clean if soiled

20 - Screw clip

21 - Intake hose

Check for secure fitting
To disengage, squeeze together at front

22 - Check-valve

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

23 - Connector

black, 2-pin
For Secondary Air Injection (AIR) Solenoid Valve -N112- or Intake Manifold Change-Over Valve -N156-
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