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    g3 Air System Aba

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    08088338
    The document provides instructions for servicing components of the secondary air injection system on vehicles from 1996. It describes the location of the secondary air injection pump motor under the intake manifold. It also provides steps for checking the pneumatic valve, secondary air injection pump motor, and secondary air injection solenoid valve using special tools like the VAG1598/18 test box and US 8026 hand vacuum pump.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    g3 Air System Aba

    Uploaded by

    08088338
    64 views15 pages
    The document provides instructions for servicing components of the secondary air injection system on vehicles from 1996. It describes the location of the secondary air injection pump motor under the intake manifold. It also provides steps for checking the pneumatic valve, secondary air injection pump motor, and secondary air injection solenoid valve using special tools like the VAG1598/18 test box and US 8026 hand vacuum pump.

    Original Description:

    aire system vw

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    The document provides instructions for servicing components of the secondary air injection system on vehicles from 1996. It describes the location of the secondary air injection pump motor under the intake manifold. It also provides steps for checking the pneumatic valve, secondary air injection pump motor, and secondary air injection solenoid valve using special tools like the VAG1598/18 test box and US 8026 hand vacuum pump.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    64 views15 pages

    g3 Air System Aba

    Uploaded by

    08088338
    The document provides instructions for servicing components of the secondary air injection system on vehicles from 1996. It describes the location of the secondary air injection pump motor under the intake manifold. It also provides steps for checking the pneumatic valve, secondary air injection pump motor, and secondary air injection solenoid valve using special tools like the VAG1598/18 test box and US 8026 hand vacuum pump.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 15

    26-16

    Secondary Air Injection (AIR)


    system, servicing
    Location of Secondary Air Injection (AIR) pump motor -V101-

    Note:

    The Secondary Air Injection (AIR) system pump motor is located under the intake
    manifold.

    1 - Intake manifold, upper section


    2 - Secondary air injection pump motor
    26-17

    Secondary air injection system,


    checking

    Function, vehicles 06.96

    The Secondary air injection system injects air


    behind the exhaust valve for approx. 30 seconds,
    depending upon engine coolant temperature,
    load, RPM and air flow rate during the cold start
    (+5 C to +40 C engine coolant temperature).

    Secondary air injection operation:

    Produces an Oxygen rich exhaust

    Causes after-burning

    Reduces the duration of the three-way catalyst


    heat-up phase

    Activation is initiated by the Motronic Engine


    Control Module (ECM) -J220- via the secondary
    air injection system pump relay -J299- to the
    solenoid valve and pneumatic valve.

    In addition to the engine cold start warm up


    phase, the secondary air injection system is
    checked via On Board Diagnostic (OBD)(up to an
    80 C engine coolant temperature, maximum).

    If the readiness code is being created, engine


    coolant temperature can be above 80 C.
    26-18

    Secondary air injection system components,


    removing and installing

    Note:

    Complete system is checked using on board diagnostic


    Repair Manual,"Fuel Injection & Ignition," Repair Group 01.

    1 - Pneumatic valve
    Checking Page 26-23
    2 - To brake servo line connector
    3 - Vacuum hose
    4 - 2-pin harness connector
    5 - Secondary Air Injection (AIR) solenoid valve
    Checking Page 26-23
    6 - Pressure hose
    Ensure it is securely seated
    7 - Secondary Air Injection (AIR) system pump motor
    bracket
    8 - 10 Nm (7 ft lb)
    9 - A/C hose bracket
    26-19

    10 - 10 Nm (7 ft lb)
    11 - 25 Nm (18 ft lb)
    12 - Secondary Air Injection (AIR) system pump motor
    Checking Page 26-21
    13 - Secondary Air Injection (AIR) pump intake hose
    14 - To Air Cleaner
    15 - To exhaust manifold union
    16 - 30 Nm (22 ft lb)
    17 - Connector tube
    18 - 10 Nm (7 ft lb)
    19 - 10 Nm (7 ft lb)
    20 - Pneumatic valve connector housing
    21 - 25 Nm (18 ft lb)
    22 - Gasket
    Always replace
    23 - Union
    26-20

    Pneumatic valve, checking

    Special tools, testers and auxiliary items

    US 8026 hand vacuum pump

    Test sequence

    - Disconnect vacuum hose from secondary air


    injection solenoid valve.

    - Attach US 8026 hand vacuum pump to vacuum


    hose.

    - Disconnect pressure line from pneumatic


    valve.

    Note:

    Do not use compressed air for the following


    check.

    - Connect auxiliary hose to pneumatic valve and


    blow into it.

    Pneumatic valve must be closed.


    - Operate hand vacuum pump.

    Valve must open and operate smoothly (without


    sticking).

    - Replace valve if necessary.


    26-21

    Secondary air injection pump motor,


    checking

    Special tools, testers and auxiliary items

    VAG1598/18 test box

    VW1594 connector test kit

    VAG1527B voltage tester

    Checking requirement

    Secondary Air Injection (AIR) pump relay


    fuse OK

    Checking sequence

    - Switch ignition OFF.

    - Connect VAG1598/18 test box to ECM wiring harness connector.


    - Disconnect pressure line from pneumatic valve.
    - Switch ignition ON.
    - Bridge test box sockets 01 and 06 using jumper wires from VW1594 adaptor kit.
    26-22

    - Connect test box terminals 49 to Ground using


    jumper wires from VW1594 adaptor kit.

    Pump motor must run and air must exit the


    pressure line.

    If pump motor runs, but no air exits hose:

    - Check pressure line, and if necessary replace


    pump motor.

    If pump motor does not run:

    - Disconnect pump motor harness connector.

    - Connect VAG1527B LED tester to disconnected


    connector using jumper wires from VW1594
    adaptor kit.

    LED tester must light up.

    If tester lights up (voltage supply OK):

    - Replace pump motor.

    If tester does NOT light up:


    - Check wiring between test box socket 49 and
    pump relay using wiring diagram.

    - Check activation of relay and wiring to pump


    motor using wiring diagram.

    - Reconnect 2-pin harness connector.

    - Check DTC memory, then erase Repair Manual,


    Fuel Injection & Ignition, Repair Group 01.
    26-23

    Secondary air injection solenoid valve,


    checking

    Special tools, testers and auxiliary items

    VW1594 adaptor kit

    VAG1527B LED tester

    US 8026 hand vacuum pump

    Checking requirement

    Vacuum hoses OK

    - Disconnect vacuum hose to solenoid valve at


    line to brake servo Page 26-18 , item 2 .

    - Connect hand vacuum pump to vacuum hose.

    - Disconnect pneumatic valve vacuum hose at


    valve Page 26-18 , item 1 .

    - Switch ignition OFF.


    - Connect VAG1598/18 test box to ECM wiring harness connector.
    - Switch ignition ON.
    - Connect test box terminals 01 and 06 using jumper wires from VW1594 adaptor
    kit.
    26-24

    - Operate hand vacuum pump.

    Vacuum must build up (valve closed).

    If vacuum does not build up:

    - Replace solenoid valve 2.

    If vacuum builds up:

    - Connect test box socket 50 to Ground using


    jumper wires from VW1594 connector test kit

    Valve must open.

    - Operate hand vacuum pump.

    Vacuum must not build up (valve open).

    If vacuum builds up:

    - Disconnect 2 pin harness connector from


    solenoid valve.

    - Connect VAG1527B LED tester to harness


    connector using jumper wires from VW1594
    adaptor kit.

    LED tester must light up.

    If tester lights up (voltage supply OK):

    - Replace solenoid valve.


    26-25

    If tester does not light up:

    - Check wiring for open circuit between test box


    socket 50 and terminal 2 of 2-pin harness
    connector using wiring diagram.

    Resistance: 1.5 maximum

    - Check wiring between central electric and


    solenoid valve harness connector (terminal 1)
    using wiring diagram.

    - Connect 2-pin harness connector.

    - Check DTC memory, then erase Repair Manual,


    Fuel Injection & Ignition, Repair Group 01.

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