Air Injection Pump Relay: Testing and Inspection

Secondary Air Injection (AIR) Pump Relay -J299- and Secondary Air Injection (AIR) Pump Motor -N101-, testing

Special tools and equipment
^ V.A.G 1526 A
^ V.A.G 1527 B
^ V.A.G 1594 A
^ V.A.G 1598/31
^ VAS 5051 with VAS 5051/1

Test sequence
- Connect vehicle diagnostic, test and information system VAS 5051 and select vehicle system "01 - Engine electronics". When doing this ignition must be on.

Display on VAS 5051:
- Select diagnosis function "03 - Final control diagnosis" from menu -1-
- Press the(arrow) button repeatedly until following display appears:

^ Secondary air pump relay (position 1 on 3-way relay carrier in electronics box in plenum chamber) should activate and Secondary Air Injection (AIR) Pump Motor -V1 01 - should run at intervals.

- Press the (arrow) button to exit from function "03 - Final control diagnosis".

A - If relay does not activate:
- Test voltage supply of secondary air pump relay.
- Test activation of secondary air pump relay.

B - If relay activates but secondary air pump motor does not run:
- Test voltage supply of secondary air pump motor.

Testing voltage supply of secondary air pump relay
- Switch ignition off.

- Remove rubber seal from plenum chamber in direction of (arrow).
- Remove plenum chamber cover -1- from front.

- Remove cover for electronics box in plenum chamber (arrows).

- Disconnect secondary air pump relay from relay position 1.

- Connect multimeter (voltage measurement range) as follows:

^ Specification: approximate battery voltage

If specification is not obtained:
- Perform following tests (marked with dots):

^ Test Fuse for secondary air pump -S130- (40 A) in electronics box in plenum chamber (position 7).
^ Test for open circuit in wiring from battery + (terminal 30) via Fuse for secondary air pump -S130- to Secondary Air Injection (AIR) Pump Relay -J299- (in 3-way relay carrier in electronics box in plenum chamber, position 1). Refer to wiring diagram.

- Eliminate open circuit in wiring (refer to wiring diagram).

Part 1:

Part 2:

- Connect multimeter (voltage measurement range) as follows:

- Operate starter briefly.
^ Specification- approximately battery voltage

If specification is not obtained:
- Perform following tests (marked with dots):

^ Test fuse -S234- (in fuse box, socket 34)
^ Test for open circuit in wiring from Secondary Air Injection (AIR) Pump Relay -J299- (located in 3-way relay carrier in electronics box in plenum chamber) to fuel pump relay via fuse -S234- (in fuse box, socket 34). Refer to wiring diagram.

- Eliminate open circuit in wiring (refer to wiring diagram).

Testing activation of secondary air pump relay
- Switch ignition off.
- Disconnect secondary air pump relay.

Part 1:

Part 2:

- Connect voltage tester VAG 1527 B as follows:
^ Vehicle diagnostic, testing and information system VAS 5051 is connected; vehicle system "01 - Engine electronics" is selected. Ignition must be switched on.

Display on VAS 5051:
- Select diagnosis function "03 - Final control diagnosis" from menu -1-
- Press the (arrow) button repeatedly until following display appears:

- Connect test box V.A.G 1598/31 to connectors on wiring harness (engine control unit remains disconnected). Also connect ground clamp of test box to battery negative terminal (not shown in illustration).

WARNING: To prevent damage to electronic components, switch to respective measuring range before connecting measuring cable and observe test prerequisites.

Part 1:

Part 2:

- Test for open circuit and short to positive or ground in following wiring connections:
- Eliminate open circuit or short circuit using wiring diagram.

If no fault is found:
- Install a new Secondary Air Injection (AIR) Pump Relay -J299-.

Testing voltage supply to secondary air pump motor

- Unplug electrical connector -1-from Secondary Air Injection (AIR) Pump Motor -V1 01 -

- Connect voltage tester V.A.G 1527 B between contacts 1 and 2.
^ Vehicle diagnostic, testing and information system VAS 5051 is connected; vehicle system "01 - Engine electronics" is selected. Ignition must be switched on.

Display on VAS 5051:
- Select diagnosis function "03 - Final control diagnosis" from menu -1-
- Press the (arrow) button repeatedly until following display appears:

Display on VAS 5051:
A - Actuator test is waiting - Continued switching required
3 - Secondary Air Injection (AIR) Pump Relay -J299-
- Press the (arrow) button.

Display on VAS 5051:
A - Actuator is running - Continued switching allowed
^ LED should flash.

- Press the (arrow) button to exit from function "03 Final control diagnosis".

If LED does not flash:
- Perform following tests (marked with dots):
^ Test for open circuit in wiring from contact 2 of connector to Secondary Air Injection (AIR) Pump Relay -J299- (in relay carrier in electronics box in plenum chamber, position 1). Refer to wiring diagram.
^ Test for open circuit in wiring from contact 1 of connector to ground (refer to wiring diagram).

- Eliminate open circuit in wiring (refer to wiring diagram).

If no fault is found:
- Replace Secondary Air Injection (AIR) Pump Motor -V101.