26-11

Secondary Air Injection (AIR)

system
WARNING!

Observe the following for all installations,

especially in engine compartment due to lack
of room:

Route lines of all types (e.g. for fuel,

hydraulic, EVAP canister system, coolant
and refrigerant, brake fluid, vacuum) and
electrical wiring so that the original path is
followed.

Watch for sufficient clearance to all moving

or hot components.

Function

Air is blown behind the exhaust valves by the

Secondary Air Injection (AIR) system for a
maximum of 100 seconds following cold start
(coolant temperature of +5 C to +33 C). This
adds oxygen to the exhaust, initiating a
secondary combustion and thereby shortening
the warm-up phase of the catalytic converter.
Activation is triggered by the motronic Engine
Control Module (ECM) -J220- and sent via the
Secondary Air Injection (AIR) pump relay -J299-
to the Secondary Air Injection (AIR) solenoid
valve -N112- (change-over valve) and the
combination valve. In addition, the Secondary Air
Injection (AIR) system is switched on for 10
seconds during idle after every subsequent
engine start (up to max. 96 C engine
temperature) and is checked via On Board
Diagnostic (OBD). Oxygen sensor control must
be active for this.
 26-12

Secondary Air Injection (AIR) system

components, removing and installing

Notes:
Components marked with * are checked via On Board
Diagnostic (OBD):

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel Injection &

Ignition, Engine Code(s): ATW, AUG, AWM, Repair Group
01, DTC memory; Engine Control Module (ECM) DTC
memory, checking and erasing

Components marked with ** are tested via output

Diagnostic Test Mode (DTM):

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel Injection &

Ignition, Engine Code(s): ATW, AUG, AWM, Repair Group
01; Output Diagnostic Test Mode (DTM); Performing output
Diagnostic Test Mode (DTM)

Secondary Air Injection (AIR) pump relay -J299- **

Page 26-16 , Fig. 1
1 - Combination valve
Checking Page 26-17
2 - Gasket
Always replace
 26-13

3 - Bracket
Bolted at cylinder head
4 - Gasket
Always replace
5 - Bracket
Bolted at intake manifold
6 - 10 Nm
7 - To recirculating valve for turbocharger -N249-
8 - From vacuum reservoir/intake manifold
connection
9 - 6 Nm
10 - Secondary Air Injection (AIR) solenoid valve -
N112-*/**
Resistance: 25 to 35
11 - Connector
2-pin
green
 26-14

12 - O-ring
Replace if damaged
13 - Pressure hose
Check for secure fitting
To disengage, squeeze together at front
14 - 8 Nm
15 - Bracket
For Secondary Air Injection (AIR) pump motor
16 - 8 Nm
17 - Secondary Air Injection (AIR) pump motor -V101-**
Checking function Page 26-19
18 - Connector
2-pin
For Secondary Air Injection (AIR) pump motor
 26-15

19 - Intake hose
For Secondary Air Injection (AIR) pump
20 - From air filter
21 - Connection tube
22 - Elbow
Secure with screw-type clamps or spring clamps
23 - Pressure line
24 - Connecting piece
Secure with screw-type clamps or spring clamps
 26-16

Fig. 1 Secondary Air Injection (AIR) pump relay -J299- (arrow)

Note:
Remove battery Ground (GND) strap if tools are necessary for removal of relays
or control modules from the relay carrier.
Obtain radio anti-theft code for radios with anti-theft coding before
disconnecting battery.
 26-17

Combination valve, checking

Special tools and equipment

VAG 1390 Hand vacuum pump

Test requirements

No DTCs in DTC memory:

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel Injection & Ignition, Engine Code
(s): ATW, AUG, AWM, Repair Group 01, DTC memory; Engine Control Module
(ECM) DTC memory, checking and erasing

Output Diagnostic Test Mode (DTM) performed:

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel Injection & Ignition, Engine Code
(s): ATW, AUG, AWM, Repair Group 01, DTC memory; Engine Control Module
(ECM) DTC memory, checking and erasing

No leaks in vacuum lines or hose connections

Vacuum hoses not clogged or kinked

 26-18

Test sequence

- Disconnect vacuum hose at combination valve (arrow) and connect VAG 1390
Vacuum pump.

Note:

Do not use pressurized air for the following test!

- Disconnect pressure hose (arrow) at Secondary Air Injection (AIR) pump motor
and blow air in with light pressure. Combination valve must close.
- Operate vacuum pump. Valve must open.

If combination valve does not open:

- Replace combination valve

 26-19

Secondary Air Injection (AIR) pump

motor, checking

Special tools and equipment

VAG 1551 Scan Tool (ST)

Note:

If VAG 1551 Scan Tool (ST) is not available, use VAG 1552 Mobile Scan Tool (ST)
instead, although this tool cannot produce a print-out.

VAG 1551/3 Cable

Test requirements

Fuse for Secondary Air Injection (AIR) pump relay -J299- OK

Intake hose for Secondary Air Injection (AIR) pump not clogged or kinked

Test sequence

- Remove noise insulation.

 Repair Manual, Body Exterior, Repair Group 50; Body, front; Noise insulation -
Assembly overview

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

 26-20

- Activate Secondary Air Injection (AIR) pump

relay via output Diagnostic Test Mode (DTM).

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel

Injection & Ignition, Engine Code(s): ATW, AUG,
AWM, Repair Group 01; Output Diagnostic Test
Mode (DTM); Performing output Diagnostic Test
Mode (DTM)

- The Secondary Air Injection (AIR) pump motor

must start up in intervals and air must exit from
exhaust tube.

If motor starts, but no air exits:

- Replace Secondary Air Injection (AIR) pump

motor.

If the Secondary Air Injection (AIR) pump motor

does not start up in intervals:

- Check activation of the Secondary Air Injection

(AIR) pump motor:
 Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel
Injection & Ignition, Engine Code(s): ATW, AUG,
AWM, Repair Group 01; Output Diagnostic Test
Mode (DTM); Performing output Diagnostic Test
Mode (DTM)
 26-21

Secondary Air Injection (AIR) valve,

checking

Test requirement

Coolant temperature 5 to 33 C

Secondary Air Injection (AIR) pump motor

OK

Test sequence

- Disconnect vacuum hose at combination valve (arrow).

- Start engine and let run at idle. When Secondary Air Injection (AIR) pump motor
starts up vacuum pressure must be noticeable at vacuum hose.

If no vacuum is felt:

- Switch off engine.

- Check activation of valve:

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel Injection & Ignition, Engine Code
(s): ATW, AUG, AWM, Repair Group 01; Output Diagnostic Test Mode (DTM);
Performing output Diagnostic Test Mode (DTM)