Air Injection: Service and Repair

Secondary air injection system components, removing and installing






Engines: AEG, (from model year 1999), AVH, AZG, BBW and BEV
1. Combi-valve
^ To replace remove warm air collector plate
2. Secondary Air Injection (AIR) pump relay - J299
^ In protective housing for relays (engine compartment) BBW engines
^ In protective housing for relays (engine compartment) AEG AVH and AZG engines
3. O-ring
^ Always replace
4. Pressure hose
^ Check if seated securely
^ Press together at front to release
5. Intake hose
^ From air cleaner upper part
^ For secondary air injection pump
^ Check if seated securely
^ Press together at front to release
6. Secondary Air Injection (AIR) pump motor
7. 10 Nm
8. Bracket
^ For secondary air injection pump motor
^ Installed on intake manifold lower part BBW engine.
^ Installed on intake manifold engines AEG AVH and AZG
9. Connector
^ 2-pin
10. 25 Nm
11. Intake manifold lower part
12. To union on exhaust manifold
13. 40 Nm BBW engine and 30 Nm AEG, AVH and AZG engines
14. Connecting pipe
15. Nuts/bolts, 60 Nm BBW engine and 35 Nm AEG, AVH and AZG engines
16. Warm air collector plate
^ With mounting for comb-valve
17. Seal
^ Always replace





Fig. 1 Position of relays in protective housing (on left in engine compartment)

1. Secondary Air Injection (AIR) pump relay -J299-1 Distinguishing features: Control number 100

Note: The relay locations may differ depending on level of equipment.

For latest control numbers and component locations:
Refer to Electrical Wiring Diagrams
^ Disconnect battery Ground strap first if tools are required to pull relays or control modules out of the relay plate.
^ Before disconnecting the battery Ground strap obtain code for radios with anti-theft coding.





Fig. 2 Secondary air pump relay -J299-, control number 100 (arrow)

^ The relay positions can vary depending on vehicle equipment
^ If tools are necessary to pull relays or control modules out of the relay plate first disconnect battery Ground (GND) strap.
^ Before disconnecting battery Ground (GND) strap obtain code for radios with anti-theft coding.