Secondary Air Injection Pump Motors, Checking

Diagnostic Procedures



Secondary Air Injection Pump Motors, Checking

Test Conditions

Fuses in right instrument panel fuse holder must be OK:

Right instrument panel fuse holder





Cylinder bank 1

• Secondary Air Injection (AIR) Pump Relay (J299), -position 2-, must be OK, check:

Relay and Secondary Air Injection pump installation location





• In E-box, plenum chamber.

Cylinder bank 2

• Secondary Air Injection (AIR) Pump Relay (J545), -position 1-, must be OK, check:

Relay and Secondary Air Injection pump installation location





• In E-box, plenum chamber.

Cylinder bank 1 and 2

• Battery voltage (both batteries) must be at least 11.5 Volts.

• All electrical consumers such as, lights and rear window defroster must be switched off.

• The Ground (GND) connections between engine and body must be OK.

• Ignition switched off.

Test Sequence

Special tools, testers and auxiliary items required

• Hand multimeter (V.A.G 1526) or Multimeter (V.A.G 1715)

• Test adapter kit (V.A.G 1594)

• Wiring diagram

• All mechanical procedures and exploded view illustrations with torque specifications are described in the engine electronics repair manual, refer to Repair Manual.

- Disconnect corresponding 2-pin connector from Secondary Air Injection (AIR) motor to be tested:





• 2-pin connector - arrow - from Secondary Air Injection (AIR) Pump Motor (V101) - 2 - (cylinder bank 1),

• 2-pin connector - arrow - from Secondary Air Injection (AIR) Pump Motor 2 (V189) - 1 - (cylinder bank 2),

• Cylinder bank 1 with cylinders 1 through 6 is located at right in direction of travel.

• Cylinder bank 2 with cylinders 7 through 12 is located at left in direction of travel.

- Disconnect corresponding pressure hose at Secondary Air Injection (AIR) pump motor to be tested.

• Secondary Air Injection (AIR) Pump Motor (V101) vacuum hose - 2 -,

• Secondary Air Injection (AIR) Pump Motor 2 (V189) vacuum hose - 1 -.

• To disengage, compress the buttons at the hose coupling.

- Connect Secondary Air Injection Pump Motor with corresponding adapter lines to positive and negative battery terminals. Secondary Air Injection Pump Motor must run and air must escape at compressed-air connection - arrow -.





If the motor does not start up, or no air or only very little air escapes:

- Disconnect connection between Secondary Air Injection Pump Motor and battery.

- Replace corresponding Secondary Air Injection pump motor:

• Secondary Air Injection (AIR) Pump Motor (V101), refer to Repair Manual,

• Secondary Air Injection (AIR) Pump Motor 2 (V189),

- Erase DTC memory of Engine Control Module => [ Diagnostic Mode 04 - Erase DTC Memory ] Diagnostic Modes 01 - 09, Diagnostic mode 4: Reset/erase diagnostic data.

- Generate readiness code => [ Readiness Code, Generating ] Monitors, Trips, Drive Cycles and Readiness Codes.

If motor starts, and air escapes:

- Disconnect connection between Secondary Air Injection Pump Motor and battery.

- Remove corresponding Secondary Air Injection pump relay from relay carrier:

• Secondary Air Injection (AIR) Pump Motor (J299) out of relay plate - 1 -,

• Secondary Air Injection (AIR) Pump Motor 2 (J545) out of relay plate - 2 -,

Relay and Secondary Air Injection pump installation location





• In E-box, plenum chamber.

• Do not remove relay from relay plate with metal tools. The terminals could conduct electricity.

- Check wire between terminal 2 of relay carrier and terminal 2 of 2-pin connector of Secondary Air Injection (AIR) Pump Motor for open circuit according to wiring diagram. Wiring resistance: max. 1.5 ohms

• Terminal 2 (terminal 87) of Secondary Air Injection (AIR) Pump Relay on relay carrier.





• Terminal 2 of 2-pin connector of Secondary Air Injection (AIR) Pump Motor.





- Check the wire for short circuit to B+ and Ground (GND). Specification: infinite ohms

- Check wire between 2-pin connector terminal 1 and Ground (GND) for open circuit according to wiring diagram. Wiring resistance: max. 1.5 ohms





- Erase DTC memory of Engine Control Module (ECM) => [ Diagnostic Mode 04 - Erase DTC Memory ] Diagnostic Modes 01 - 09, Diagnostic mode 4: Reset/erase diagnostic data.

- Generate readiness code => [ Readiness Code, Generating ] Monitors, Trips, Drive Cycles and Readiness Codes.

If no malfunction is detected in the wiring:

Cylinder bank 1

- Replace Engine Control Module (ECM) (J623),

Cylinder bank 2

- Replace E ngine Control Module (ECM) 2 (J624),