Air Injection: Service and Repair

Secondary Air Injection system components, removing and installing

Notes:
^ Components marked with an * are checked via the On Board Diagnostic II system
^ Components marked with ** are checked via Output Diagnostic Test mode

1- Combi-valve Checking
^ Removing and installing:
2- Vacuum hose
3- 2-pin harness connector
4- Secondary Air Injection valve N112*/**
^ fastened to closeout panel
5- To connection on pipe to brake booster
6- Secondary Air Injection pump motor relay J299 */**
^ in fuse/relay panel (slide in wire routing next to brake master cylinder
7- O-ring
^ Replace
8- Pressure hose
^ Ensure it is tightly seated
^ Press together at front to release
9- Intake hose
^ for Secondary Air Injection pump
10- to Air Cleaner
11- Secondary Air Injection pump motor V101**
^ Checking => Refer to Secondary Air Injection pump motor, checking.
12- 25 Nm (18 ft. lbs.)
13- 10 Nm (7 ft. lbs. )
14- Bracket
^ for Secondary Air Injection pump motor
^ Attached to intake manifold
15- 2-pin harness connector
16- Fuel rail - lower section
17- To union on exhaust manifold
18- 30 Nm (22 ft. lbs.)
19- Pipe
20- Warm air collector plate with mounting for combi-valve
21- Gasket
^ Replace

Combi-valve, removing and installing
Special tools, workshop equipment, testers, measuring instruments and auxiliary items required





^ VAG 1331 Torque wrench 5 to 50 Nm (3.7 to 37 ft. lbs.)
^ VAS 5085 conductor

Notes:
^ Always replace all seals and gaskets
^ A second technician is required for installation.

Removing from above
- Remove engine cover.
- Remove intake hose between Air Cleaner and Secondary Air Injection pump motor.
- Remove pressure and vacuum hoses from combi-valve.
- Loosen bolted connection on connecting pipe

Removing from below
- If installed, remove protective cap from right inner CV joint.
- Unscrew connector pipe from exhaust manifold.
- Unscrew combi-valve. Use steering insert and 4 mm inner hex socket.

Installing
- Thread front bolts through the heat shield from below using auxiliary tool.
- Have second technician hold screw tight from above.
- Install 4 mm inner hex with steering insert in screw head.
- Have second mechanic position combi-valve from above and also guide it during fastening of second bolt.
^ tightening torque 10 Nm (7 ft. lbs.)

Note:
Assembly is the reverse of the disassembly procedure.