Components of the secondary air system, removing and installing: Notes

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2005 Volkswagen GTI, 2004 Volkswagen Jetta, 2004 Volkswagen GTI, 2003 Volkswagen Jetta, and 2003 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Components marked with an are checked by On Board Diagnostic (OBD): → 01 ON BOARD DIAGNOSTIC (OBD)
Components marked with are checked by output Diagnostic Test Mode (DTM): → 01 ON BOARD DIAGNOSTIC (OBD)
Secondary Air Injection (AIR) pump relay J299 ^/Position of relays in protective housing (on left in engine compartment) , Position of relays in protective housing (on left in engine compartment)

Fig 1: Secondary Air System Components

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Intake manifold

2 - Vacuum actuator

For variable intake manifold change-over

3 - To intake manifold

4 - To fuel pressure regulator

5 - Combi-valve

Checking → Combi-valve, checking

6 - Gasket

Replace

7 - Air channel

In cylinder head

8 - 8 Nm

9 - Ground connection

Check for secure seating

10 - Unions

For combi-valve and coolant hose
Coolant hose connection diagram → Coolant hose connection diagram

11 - 5 Nm

12 - Pressure hose

Check seated securely
Press together at front to release

13 - O-ring

Replace if damaged

14 - Union

15 - Air cleaner

Clean if dirty

16 - Retaining clip

17 - Bracket

For secondary air pump motor
Secured to oil pan and cylinder block

18 - 20 Nm

19 - Rubber bushing

20 - Secondary Air Injection (AIR) pump motor V101

Checking → Secondary Air Injection (AIR) pump motor V101 , checking

21 - Intake hose

Check for secure seating
Press together at front to release

22 - Connector

Black, 2-pin
For intake manifold change-over valve
Mark connector and component before pulling connector off.

23 - Connector

Black, 2-pin
For secondary air solenoid valve
Mark connector and component before pulling connector off.

24 - Intake Manifold Change-Over valve N156

Valve is activated by engine control module (pulsed)

25 - Secondary Air Injection (AIR) solenoid valve N112 ^/

Valve is activated by engine control module (pulsed)

26 - Vacuum reservoir

27 - Non-return valve

Observe installation position
White connector faces Secondary air injection solenoid valve N112 / Intake manifold change-over valve N156

28 - Connector

Black, 2-pin
For secondary air injection pump motor