Air Injection Pump Relay: Testing and Inspection

Secondary Air Injection (AIR) Pump Relay -J299- And Activation, Checking







Special tools and equipment
- VAG1526A Multimeter
- VAG1527B Voltage tester
- VAG1594A Connector test kit
- VAG1598/31 Test box
- VAS5051 Vehicle diagnosis, testing and information system with VAG5051/1 Adapter

Requirement
- VAS5051 tester connected and vehicle On Board Diagnostic (OBD) function 01 "Engine electronics" selected.

Work sequence
- Initiate output Diagnostic Test Mode (DTM) and activate Secondary Air Injection (AIR) pump relay -J299-.







- Secondary Air Injection (AIR) pump relay -3- (in E-box, plenum chamber) must engage and Secondary Air Injection (AIR) pump relay -J299- must run in intervals

A. Does not engage relay:
- Check voltage supply of Secondary Air Injection (AIR) pump relay.
- Check activation of Secondary Air Injection (AIR) pump relay.

B. If relay triggers, but Secondary Air Injection (AIR) pump motor does not run:
- Check voltage supply of Secondary Air Injection (AIR) pump motor.

Checking voltage supply of Secondary Air Injection (AIR) pump relay
- Switch ignition off.







- Pull rubber seal off of plenum chamber cover in direction of arrow.
- Remove plenum chamber cover -1- toward front.







- Pry off both covers -3- using a screwdriver.
- Loosen hex-nuts -4- by several turns.
- Loosen wiper arm -2- by lightly tilting from wiper axle.
- Remove hex nuts completely and remove wiper arms.
- Disconnect securing clips -1- and remove cowl grille -5-.







- Remove E-box cover in plenum chamber (arrows).







- Pry off Engine Control Module (ECM) retaining bracket (arrows) using a screwdriver and set control module aside.
- If installed, unclip Transmission Control Module (TCM) retaining bracket and set control module aside.







- Remove Secondary Air Injection (AIR) pump relay -3-.







- Connect multimeter for voltage measurement as follows.

Relay carrier in E-box, plenum chamber, Measure to
position 3
Terminal
8 Engine Ground (GND)

Specification: approx. battery voltage

If specified value is not obtained:
- Perform following tests marked with dots:







- Check Fuse for secondary air pump -S130- (40 A) in E-Box, plenum chamber, position B.
- Check wire connection from battery + (terminal 30) via Fuse for secondary air pump -S130- to Secondary Air Injection (AIR) pump relay -J299- (in relay and fuse carrier in E-Box, plenum chamber, position 3) for open circuit.







- Connect multimeter for voltage measurement as follows.

Relay carrier in E-box, plenum chamber, Measure to
position 3
Terminal
4 Engine Ground (GND)


- Operate starter briefly.

Specification: approx. battery voltage

If specified value is not obtained:
- Perform following tests marked with dots:







- Check fuse -S234- in fuse holder (position 34).
- Check wire connection from Secondary Air Injection (AIR) pump relay -J299- (in 3-socket relay carrier in E-box, plenum chamber) via Fuse in fuse holder -S234- (position 34) to Fuel Pump (FP) relay for open circuit:


Check activation of the Secondary Air Injection (AIR) pump relay
- Switch ignition off.
- Remove Secondary Air Injection (AIR) pump relay







- Connect VAG1527B voltage tester as follows:

Relay carrier in E-box, plenum chamber, Measure to
position 3
Terminal
6 Engine Ground (GND)

- Initiate output Diagnostic Test Mode (DTM) and activate Secondary Air Injection (AIR) rump relay -J299-.
- LED must blink

If LED does not blink:
- Switch ignition off.







- Connect VAG1598/31 test box to harness connectors of wiring harness (do not connect ECM). Connect Ground (GND) clip at test box (not visible in illustration) to Ground (GND).







- Check following wire connection for open circuit and short circuit to Ground (GND) and B+:

Relay carrier in E-box, plenum chamber, VAG1598/31 test box
position 3 Socket
Terminal
6 46

- Repair open circuit or short circuit if necessary.

If no malfunctions are detected:
- Replace Secondary Air Injection (AIR) pump relay -J299-.

Check voltage supply of the Secondary Air Injection (AIR) pump motor







- For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of auxiliary heater at sound insulation.







- Remove bolts or release quick-release screws -1- and -2- and remove front sound insulation.







- Disconnect electrical harness connector -2- at Secondary Air Injection (AIR) pump motor -V101-, -1-.







- Connect VAG1527B voltage tester between terminals 1 and 2
- Initiate output Diagnostic Test Mode (DTM) and activate Secondary Air Injection (AIR) pump relay -J299-.
- LED must blink

If LED does not blink:
- Perform following tests marked with dots:
- Check wire connection from terminal 2 of connector to Secondary Air Injection (AIR) pump relay -J299- (in relay carrier in E-Box, plenum chamber, position 3) for open circuit.
- Check wire connection from terminal 1 of connector to Ground (GND) for open circuit:

If no malfunctions are detected:
- Replace Secondary Air Injection (AIR) pump motor -V101-.