Secondary Air Injection (AIR) pump motor, checking

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.

Recommended special tools and equipment

V.A.G 1526 multimeter or V.A.G 1715 multimeter
V.A.G 1594 connector test kit
Wiring diagram

Test requirements

Fig 1: Identifying Main Fuse Panel

Courtesy of VOLKSWAGEN UNITED STATES, INC.

The respective fuses of Secondary Air Injection (AIR) Pump Motor -V101- must be OK:

Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations

Fuel Pump (FP) Relay -J17- must be OK, check:

Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations

Secondary Air Injection (AIR) Pump Relay -J299- must be OK, check:

Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations

Battery voltage must be at least 11.5 volts.
All electrical consumers such as, for example, lights and rear window defroster must be switched off.
Ground (GND) connections between engine and chassis must be OK.
Ignition switched off.

Test sequence

Remove front noise insulation.

Vehicles with engine code AFP

Fig 2: Locating 2-Pin Connector At Motor (Vehicles With Engine Code AFP)

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Disconnect 2-pin connector from motor for secondary air pump (arrow).

Vehicles with engine code BDF

Fig 3: Locating 2-Pin Connector At Motor (Vehicles With Engine Code BDF)

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Disconnect 2-pin connector from motor for secondary air pump (arrow).

Vehicles with engine code BJS

Fig 4: Locating 2-Pin Connector At Motor (Vehicles With Engine Code BJS)

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Disconnect 2-pin connector from motor for secondary air pump (arrow).

Continuation for all vehicles

Disconnect pressure hose at Secondary Air Injection (AIR) pump motor.

NOTE: To disengage, compress the buttons at the hose coupling.

Fig 5: Secondary Air Injection Pump Motor Connected To The B+ And Ground Terminals Of The Battery

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Connect Secondary Air Injection (AIR) Pump Motor to the B+ and Ground (GND) terminals of the battery using the respective adapter cables.

The Secondary Air Injection (AIR) Pump Motor must start up and air must escape at compressed-air connection (arrow).

If the motor does not start up, or no air or only very little air escapes:

Disconnect connection between Secondary Air Injection (AIR) Pump Motor and battery.
Replace Secondary Air Injection (AIR) Pump Motor -V101-:

Vehicles with engine code AFP. Refer to Parts of Secondary Air Injection (AIR) system (vehicles with engine code AFP), removing and installing , item 19
Vehicles with engine code BDF. Refer to Parts of Secondary Air Injection (AIR) system (vehicles with engine code BDF), removing and installing , item 20
Vehicles with engine code BJS. Refer to Parts of Secondary Air Injection (AIR) system (vehicles with engine code BJS), removing and installing , item 18

Erase DTC memory of Engine Control Module (ECM). Refer to Diagnostic mode 4: Reset/erase diagnostic data
Generate readiness code. Refer to Readiness code, generating

If motor starts, and air escapes:

Disconnect connection between Secondary Air Injection (AIR) Pump Motor and battery.
Remove Secondary Air Injection (AIR) pump relay from relay carrier in protective housing for control modules:

Vehicles with engine code AFP. Refer to Relay position assignment in protective housing (engine compartment, left) ,
Vehicles with engine code BDF. Refer to Relay position assignment in protective housing (engine compartment, left) ,
Vehicles with engine code BJS. Refer to Relay position assignment in protective housing (engine compartment, left) .

Fig 6: Checking Wire Between Terminal 2 Of Relay Carrier And Terminal 2 Of 2-Pin Connector Of Secondary Air Injection Pump Motor

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Check wire between terminal 2 of relay carrier and terminal 2 of 2-pin connector of Secondary Air Injection (AIR) Pump Motor for open circuit according to wiring diagram.

Wire resistance: max. 1.5 Ω

Also check the wire for short circuit to B+ and Ground (GND).

Specified value: ∞ Ω

Vehicles with engine code AFP

Fig 7: 2-Pin Electrical Harness Connector & Terminals

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Check wire between 2-pin connector terminal 1 and Ground (GND) for open circuit according to wiring diagram.

Wire resistance: max. 1.5 Ω

Vehicles with engine codes BDF and BJS

Fig 8: 2-Pin Electrical Connector & Terminals

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Check wire between 2-pin connector terminal 1 and Ground (GND) for open circuit according to wiring diagram.

Wire resistance: max. 1.5 Ω

Continuation for all vehicles

Erase DTC memory of Engine Control Module (ECM). Refer to Diagnostic mode 4: Reset/erase diagnostic data
Generate readiness code. Refer to Readiness code, generating

If no malfunctions are found in wires:

Replace Motronic Engine Control Module (ECM) -J220-. Refer to Engine Control Module (ECM), replacing .