Volkswagen Golf 3 / Jetta 3 - Engine: ABA. Exhaust system:Secondary Air Injection (AIR) System (eng.)

Volkswagen Golf 3 / Jetta 3 - Engine: ABA. Exhaust system:Secondary Air Injection (AIR) System (eng.)
26-16
Secondary Air Injection (AIR)
system, servicing
Location of Secondary Air Injection (AIR) pump motor -V101Note:
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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