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3.2l - Exhaust System, Emission Controls - Engine Code(s): Bub & Cbra Audi A3 8P рестайлинг

Exhaust 50 illustrations ~3235 words

Note. After exhaust system repairs, make sure exhaust system is not under stress and is far enough from the body. If necessary, loosen clamping sleeve and align muffler and exhaust pipe so that there is adequate distance to body and that weight is evenly distributed among the suspended mounts. Loosen and tighten clamping washers for heat shields using a screwdriver. Tightening Specification: 2 Nm

PRINCIPLE AND FUNCTION

Principle

Due to the rich mixture during the cold start phase, the exhaust emissions contain an increased level of unburned hydrocarbons. The Secondary Air Injection (AIR) system improves the secondary oxidation within the catalytic converter, thereby reducing harmful emissions. The heat released by secondary oxidation shortens the start-up time of the catalytic converter considerably, as well as significantly improves emissions quality during the cold-running phase.

Function

  1. During cold start (with coolant temperatures +15 °C to +35 °C / +59 °F to +95 °F), Secondary Air Injection (AIR) system blows air behind exhaust valve for approximately 65 seconds. This produces an oxygen rich exhaust gas, causes after burning and reduces the heating-up phase of the catalytic converter.
  2. In addition, the Secondary Air Injection (AIR) system is switched on with a delay of approximately 20 seconds during idle for 5 seconds after every subsequent engine start up to max. 80 °C / 176 °F coolant temperature and is checked via On Board Diagnostic (OBD).
  3. The motronic control module -J220- controls the secondary air pump motor -V101- to the secondary air pump relay -J299-.

Scheme 9

Scheme 9: EXHAUST SYSTEM COMPONENT OVERVIEW
  1. Bracket For exhaust system
  2. Retaining Loop Replace if damaged
  3. 23 Nm
  4. Center Muffler Unit with rear muffler Install exhaust system free of stress, refer to «EXHAUST SYSTEM, INSTALLING»(/audi/a3/8p-2004-2008/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-bub-cbra__exhaust-system-installing)
  5. Retaining Loop Replace if damaged
  6. 23 Nm
  7. Bracket for Exhaust System
  8. 25 Nm
  9. Suspended Mount Replace if damaged
  10. 40 Nm Replace
  11. Seals Replace
  12. Front Exhaust Pipe Support
  13. 25 Nm
  14. 40 Nm
  15. Oxygen Sensor Before Catalytic Converter 2 pieces The threads of new oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body When re-using the old oxygen sensor, grease the threads with hot bolt paste; the paste must not get into slots of oxygen sensor body; hot bolt paste Removal and installation, refer to «Removal and Installation»(/audi/a3/8p-2004-2008/remont/fuel-system/#32l-fuel-injection-system-engine-codes-bub-cbra)
  16. Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) 2 pieces The threads of new oxygen sensors are coated with assembly paste; the paste must not get into slots of oxygen sensor body When re-using the old oxygen sensor, grease the threads with hot bolt paste; the paste must not get into slots of oxygen sensor body; hot bolt paste. Removal and installation, refer to «Removal and Installation»(/audi/a3/8p-2004-2008/remont/fuel-system/#32l-fuel-injection-system-engine-codes-bub-cbra)
  17. Front Exhaust Pipe With Catalytic Converters and Front Muffler Do not bend the flex joint more than 30° or it will get damaged. Do not load decoupling element on cable Do not damage wire mesh at decoupling element Protect catalytic converter from shocks and impact stress Removal and installation, refer to «FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER»(/audi/a3/8p-2004-2008/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-bub-cbra__front-exhaust-pipe-with-catalytic-converters) Remove decoupling element guard on replacement part as late as possible Install exhaust system free of stress, refer to «EXHAUST SYSTEM, INSTALLING»(/audi/a3/8p-2004-2008/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-bub-cbra__exhaust-system-installing)
  18. Clamping Sleeve Before tightening, ensure exhaust system is tension-free, refer to «EXHAUST SYSTEM, INSTALLING»(/audi/a3/8p-2004-2008/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-bub-cbra__exhaust-system-installing) Installed location (Scheme 10) Tighten bolts evenly
  19. 40 Nm Replace
  20. 23 Nm
  21. Suspended Mount Replace if damaged
  22. Rear Muffler Unit with center muffler Install exhaust system free of stress, refer to «EXHAUST SYSTEM, INSTALLING»(/audi/a3/8p-2004-2008/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-bub-cbra__exhaust-system-installing)
  23. Retaining Loop Replace if damaged
  24. 23 Nm
  25. Bracket for Exhaust System

Scheme 10

Scheme 10

Install clamping sleeve horizontally.

  1. Threaded connection points toward the right.

Scheme 11

Scheme 11: EXHAUST MANIFOLD COMPONENT OVERVIEW
  1. 23 Nm Replace
  2. Exhaust Manifold Removal and installation, refer to «EXHAUST MANIFOLD»(/audi/a3/8p-2004-2008/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-bub-cbra__exhaust-manifold)
  3. Gasket Replace
  4. Gasket With heat shield Replace
  5. Heat Shield
  6. 10 Nm
  7. Bracket Depending on the version, riveted with a heat shield
  8. 20 Nm
  9. Bracket
  10. 10 Nm

SECONDARY AIR INJECTION COMPONENT OVERVIEW

Note. Secondary Air Injection (AIR) Pump Relay -J299- location (Scheme 14) Installation location of secondary air injection (AIR) pump fuse (Scheme 15).

Scheme 12

Scheme 12: VEHICLES WITH ENGINE CODE BUB
  1. Secondary Air Injection (AIR) Pump Motor -V101- Removal and installation, refer to «SECONDARY AIR INJECTION PUMP»(/audi/a3/8p-2004-2008/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-bub-cbra__secondary-air-injection-pump)
  2. Rubber Bushing
  3. 9 Nm
  4. Bracket For Secondary Air Injection (AIR) pump motor -V101
  5. 9 Nm
  6. 9 Nm
  7. Secondary Air Hose Check for secure seat
  8. Gasket Replace
  9. Connection For coolant and secondary air injection (AIR) combi-valve
  10. 9 Nm
  11. 9 Nm
  12. Gasket Replace
  13. Secondary Air Injection (AIR) Combination Valve Checking, refer to «SECONDARY INJECTION COMBINATION VALVE, CHECKING FOR FUNCTION AND LEAKS»(/audi/a3/8p-2004-2008/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-bub-cbra__secondary-injection-combination-valve-checking-for) Removal and installation, refer to «SECONDARY AIR INJECTION (AIR) COMBINATION VALVE»(/audi/a3/8p-2004-2008/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-bub-cbra__secondary-air-injection-air-combination-valve)
  14. O-ring Replace if damaged
  15. Secondary Air Hose Check for secure seat
  16. O-ring Replace if damaged
  17. O-ring Replace if damaged
  18. Connecting Piece To air filter
  19. Air Filter Housing Clean if contaminated

Scheme 13

Scheme 13: VEHICLES WITH ENGINE CODE CBRA
  1. Secondary Air Injection (AIR) Pump Motor -V101- Removal and installation, refer to «SECONDARY AIR INJECTION PUMP»(/audi/a3/8p-2004-2008/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-bub-cbra__secondary-air-injection-pump)
  2. Rubber Bushing
  3. 9 Nm
  4. Bracket For secondary air injection (AIR) pump motor -V101
  5. 9 Nm
  6. 9 Nm
  7. Hose Check for secure seat
  8. Vacuum Hoses
  9. Secondary Air Injection (AIR) Solenoid Valve 2 -N320- Component location (Scheme 16)
  10. Vacuum Hoses
  11. Secondary Air Injection (AIR) Solenoid Valve -N112- Component location (Scheme 16)
  12. Gasket Replace
  13. Connection For coolant and left secondary air injection (AIR) combination valve
  14. 9 Nm
  15. Gasket Replace
  16. Connection For right Secondary Air Injection (AIR) combination valve
  17. 9 Nm
  18. Hose Check for secure seat
  19. 9 Nm
  20. Connection For right Secondary Air Injection (AIR) combination valve
  21. 9 Nm
  22. Gasket Replace
  23. Right Secondary Air Injection (AIR) Combination Valve Checking, refer to «SECONDARY INJECTION COMBINATION VALVES, CHECKING FOR FUNCTION AND LEAKS»(/audi/a3/8p-2004-2008/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-bub-cbra__secondary-injection-combination-valves-checking-for) Removal and installation, refer to «SECONDARY AIR INJECTION RIGHT COMBINATION VALVE»(/audi/a3/8p-2004-2008/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-bub-cbra__secondary-air-injection-right-combination-valve)
  24. Gasket Replace
  25. 9 Nm
  26. Angle Piece For right Secondary Air Injection (AIR) combination valve
  27. Hose Check for secure seat
  28. 9 Nm
  29. Pipe
  30. Gasket Replace
  31. Left Secondary Air Injection (AIR) Combination Valve Checking, refer to «SECONDARY INJECTION COMBINATION VALVES, CHECKING FOR FUNCTION AND LEAKS»(/audi/a3/8p-2004-2008/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-bub-cbra__secondary-injection-combination-valves-checking-for) Removal and installation, refer to «SECONDARY AIR INJECTION LEFT COMBINATION VALVE»(/audi/a3/8p-2004-2008/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-bub-cbra__secondary-air-injection-left-combination-valve)
  32. Gasket Replace
  33. 9 Nm
  34. O-ring Replace if damaged
  35. Secondary Air Injection Sensor 1 -G609- Removal and installation, refer to «SECONDARY AIR INJECTION SENSOR 1»(/audi/a3/8p-2004-2008/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-bub-cbra__secondary-air-injection-sensor-1)
  36. 3.5 Nm
  37. O-ring Replace
  38. Pipe
  39. 9 Nm
  40. O-ring Replace if damaged
  41. O-ring Replace if damaged
  42. Connecting Piece To air filter
  43. Air Filter Housing Clean if soiled

Scheme 14

Scheme 14
  1. In E-box, engine compartment.

3 - Secondary Air Injection (AIR) pump relay -J299

Scheme 15

Scheme 15
  1. In E-box, engine compartment.

F - 40 A secondary air injection (AIR) pump motor -V101- fuse

Scheme 16

Scheme 16
  1. On vacuum reservoir at front on the intake manifold.
  1. Secondary air injection (AIR) solenoid valve -N112
  2. Secondary air injection (AIR) solenoid valve 2 -N320- - engine code CBRA only

FASTENER TIGHTENING SPECIFICATIONS

ComponentBolt SizeNm
Angle Piece for Right Secondary Air Injection (AIR) Combination Valve9
Bracket (5)20
Bracket (6)10
Bracket for Exhaust System23
Bracket for Secondary Air Injection (AIR) Pump Motor
Bolt9
Nut9
Clamping Sleeve, Nut40 (2)
Connection for Coolant and Secondary Air Injection (AIR) Combi-Valve, Eng. Code BUB (7)9
Connection for Coolant and Left Secondary Air Injection (AIR) Combination Valve, Eng. Code CBRA (8)9
Connection for Right Secondary Air Injection (AIR) Combination Valve, Eng. Code CBRA9
Exhaust Manifold, Nut23 (2)
Exhaust Manifold Heat Shield to Cylinder Head20
Front Exhaust Pipe Support
25 (1)
40 (1)
Front Exhaust Pipe With Catalytic Converters and Front Muffler, Nut40 (2)
Heat Shield10
Oxygen Sensor in Front Exhaust Pipe55
Pipe9
Secondary Air Injection (AIR) Combination Valve on the Bracket or Connector9
Secondary Air Injection (AIR) Pump BracketM610
To Cylinder BlockM820
Secondary Air Injection Sensor 1 to Pipe3.5
Suspended Mount (4)25 (2)
Suspended Mount (3)23 (3)
Throttle Valve Control Module to Intake Manifold10
(1) For bolt tightening clarification, refer to EXHAUST SYSTEM COMPONENT OVERVIEW and see items -13 and 14- (2) Always replace (3) For bolt tightening clarification, refer to EXHAUST SYSTEM COMPONENT OVERVIEW and see items -21- (4) For bolt tightening clarification, refer to EXHAUST SYSTEM COMPONENT OVERVIEW and see items -9- (5) For bolt tightening clarification, refer to EXHAUST MANIFOLD COMPONENT OVERVIEW and see items -7- (6) For bolt tightening clarification, refer to EXHAUST MANIFOLD COMPONENT OVERVIEW and see items -9- (7) For bolt tightening clarification, refer to Vehicles with engine code BUB and see item -9- (8) For bolt tightening clarification, refer to Vehicles with engine code CBRA and see item -13
(1)For bolt tightening clarification, refer to EXHAUST SYSTEM COMPONENT OVERVIEW and see items -13 and 14
(2)Always replace
(3)For bolt tightening clarification, refer to EXHAUST SYSTEM COMPONENT OVERVIEW and see items -21
(4)For bolt tightening clarification, refer to EXHAUST SYSTEM COMPONENT OVERVIEW and see items -9
(5)For bolt tightening clarification, refer to EXHAUST MANIFOLD COMPONENT OVERVIEW and see items -7
(6)For bolt tightening clarification, refer to EXHAUST MANIFOLD COMPONENT OVERVIEW and see items -9
(7)For bolt tightening clarification, refer to Vehicles with engine code BUB and see item -9
(8)For bolt tightening clarification, refer to Vehicles with engine code CBRA and see item -13

EXHAUST SYSTEM, CHECKING FOR LEAKS

Start engine and let run at idle.

Seal tailpipes with cloths or plug for the duration of the leak test.

Check for leaks by listening at connection areas of cylinder head/exhaust manifold, exhaust manifold/front exhaust pipe etc.

Repair detected leaks.

EXHAUST FLAP VACUUM DIAPHRAGM, CHECKING

Special tools and workshop equipment required

  1. Hand Vacuum Pump VAS 6213

Test Sequence

  1. Vacuum lines and hose connections free of leaks.
  2. Vacuum lines not plugged.

Disconnect hose on vacuum diaphragm for exhaust flap at rear muffler.

Connect hand vacuum pump to vacuum diaphragm.

Scheme 17

Scheme 17

Generate vacuum using hand vacuum pump.

Scheme 18

Scheme 18
  1. Linkage must move upward.

Vent the hand vacuum pump.

  1. Linkage must move downward.

If linkage does not move

Check the linkage for ease of movement and check the vacuum diaphragm for leaks.

SECONDARY INJECTION COMBINATION VALVE, CHECKING FOR FUNCTION AND LEAKS

Procedure

  1. Vacuum lines and hose connections free of leaks.
  2. Vacuum lines not plugged.

Disconnect the secondary air hose -arrow- and connect the assisting hose into the hose leading to the secondary air combination valve.

Scheme 19

Scheme 19

Blow lightly into assisting hose by mouth, do not use compressed air.

  1. Secondary Air Injection (AIR) combination valve must be closed, it must not be possible to blow through.

Blow more strongly into assisting hose by mouth, do not use compressed air.

  1. The Secondary Air Injection (AIR) combination valve must open, it must be possible to blow through.

If the switch point cannot be detected, replace secondary air injection (AIR) combination valve. Refer to SECONDARY AIR INJECTION (AIR) COMBINATION VALVE .

SECONDARY INJECTION COMBINATION VALVES, CHECKING FOR FUNCTION AND LEAKS

Special tools and workshop equipment required

  1. Hose Clamps Up to 25 mm Dia.3094 for the left Secondary Air Injection (AIR) combination valve
  2. Hand Vacuum Pump VAS 6213

Procedure

  1. Vacuum lines and hose connections free of leaks.
  2. Vacuum lines not plugged.

Left secondary air injection (AIR) combi-valve

Scheme 20

Scheme 20

Remove the air guide tube -arrows-.

Note. Ignore -1-.

Remove the rear vacuum hoses -1, 2, 4- from the intake manifold.

Scheme 21

Scheme 21

Remove wiring connection from intake manifold -arrows- and lay back with hoses connected.

Note. Ignore -3-.

Remove the Secondary Air Injection (AIR) hose -arrow-, pull it up and clamp it off with 3094.

Scheme 22

Scheme 22

Disconnect the vacuum hose from the secondary air injection (AIR) combination valve.

Scheme 23

Scheme 23

Connect the VAS 6213 to the secondary air injection (AIR) combination valve vacuum connection.

Disconnect the secondary air injection (AIR) hose the marked location -arrow-.

Blow into the secondary air injection (AIR) hose using light pressure (do not use pressurized air).

  1. Secondary air injection (AIR) combination valve must be closed, it must not be possible to blow through.

Run the hand vacuum pump to generate a vacuum.

  1. The secondary air injection (AIR) combination valve must open, it must be possible to blow through.

If the left secondary air injection (AIR) combination valve does not react as described, replace it. Refer to SECONDARY AIR INJECTION LEFT COMBINATION VALVE .

Right secondary air injection (AIR) combi-valve

Scheme 24

Scheme 24

Remove the right secondary air injection combination valve. Refer to SECONDARY AIR INJECTION RIGHT COMBINATION VALVE .

Connect the VAS 6213 to the right Secondary Air Injection (AIR) combination valve vacuum connection -1-.

Connect a suitable assisting hose to the secondary air combination valve -2-.

Blow lightly into the assisting hose by mouth, do not use compressed air.

  1. Secondary air injection (AIR) combination valve must be closed, it must not be possible to blow through.

Run the hand vacuum pump to generate a vacuum.

  1. The secondary air injection (AIR) combination valve must open, it must be possible to blow through.

If the right secondary air injection (AIR) combination valve does not react as described, replace it. Refer to SECONDARY AIR INJECTION RIGHT COMBINATION VALVE .

Assembling

Assembly is in reverse order of removal, note the following

Install the right secondary air injection combination valve. Refer to SECONDARY AIR INJECTION RIGHT COMBINATION VALVE .

FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER

Special tools and workshop equipment required

  1. Ring Spanner 7-Piece Set For Oxygen Sensor 3337

Removing

If equipped, remove vacuum hose -2- to air guide hose.

Scheme 25

Scheme 25

Disconnect air guide hose -1- at throttle valve control module -J338-.

Disconnect mass air flow (MAF) sensor -G70- electrical connector -3-.

Remove upper section of air filter housing -arrows-.

Remove filter element.

Pull off air guide cover -1-, disengage clips sideways to do so.

Scheme 26

Scheme 26

Unclip air duct -2-.

Remove lower section of air filter housing -arrows-.

Scheme 27

Scheme 27

Disconnect electrical connectors -1- and -2- for heated oxygen sensor (HO2S) -G39- (in front of catalytic converter) and heated oxygen sensor (HO2S) 2 -G108- (in front of catalytic converter).

Scheme 28

Scheme 28

Free up electrical wiring to oxygen sensors.

Remove heated oxygen sensor (HO2S) 2 -G108- -1- and heated oxygen sensor (HO2S) -G39- -2-.

Scheme 29

Scheme 29

Remove bolts -1- and -3- and remove front exhaust pipe support -2-.

Scheme 30

Scheme 30

Remove front exhaust pipe nuts accessible from top from exhaust manifolds -arrows-.

Scheme 31

Scheme 31

Remove center noise insulation fasteners -1 to 3-.

Scheme 32

Scheme 32

Remove right noise insulation fasteners -1 to 3-.

Scheme 33

Scheme 33

Remove the right vehicle underbody cover -arrows-.

Scheme 34

Scheme 34

Disconnect electrical connectors -1- and -2- at right of vehicle floor.

Scheme 35

Scheme 35

Remove connection coupling from bracket and free up wiring to oxygen sensor (O2S) behind three way catalytic converter (TWC) -G130- and oxygen sensor (O2S) 2 behind three way catalytic converter (TWC) -G131-.

Remove front exhaust pipe nuts accessible from bottom from exhaust manifolds -arrows-.

Remove front vehicle floor crossmember by removing nuts -1- and -2-.

Scheme 36

Scheme 36

Note. Do not bend the flex joints in front of the exhaust pipe more than 30° or they may be damaged.

Separate exhaust system at clamping sleeve -3-.

Remove exhaust system bracket -arrows- and remove exhaust system.

Scheme 37

Scheme 37

Remove front exhaust pipe with catalytic converter and front muffler.

Installing

Installation is in reverse order of removal, note the following.

Note. Replace gaskets and self-locking nuts.

Align exhaust system free of tension. Refer to EXHAUST SYSTEM, INSTALLING .

Tightening Specifications

ComponentNm
Front Exhaust Pipe to Exhaust Manifold40 (1)
Catalytic Converter to Front Exhaust Pipe23 (1)
Oxygen Sensor in Front Exhaust Pipe55
Exhaust System Bracket to Subframe23
(1) Replace bolts and nuts.
(1)Replace bolts and nuts.

EXHAUST MANIFOLD

Removing

Note. All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

Remove the intake manifold. Refer to Removal and Installation .

Remove heat shield over exhaust manifold -arrows-.

Scheme 38

Scheme 38: EXHAUST MANIFOLD

Remove bolts -1- and -3- and remove front exhaust pipe support -2-.

Note. Do not bend the flex joints in front of the exhaust pipe more than 30° or they may be damaged.

Remove front exhaust pipe at exhaust manifolds -arrows- and slide back slightly.

Note. Oxygen sensors remain installed.

Remove 7 nuts each -arrows- at both exhaust manifolds and remove washers.

Scheme 39

Scheme 39

Remove exhaust manifold toward back.

Installing

Installation is in reverse order of removal, note the following

Note. Replace gaskets and self-locking nuts.

Install intake manifold. Refer to Removal and Installation .

Tightening Specifications

ComponentNm
Exhaust Manifold to Cylinder Head23 (1)
Front Exhaust Pipe to Exhaust Manifold40 (1)
Exhaust Manifold Heat Shield to Cylinder Head20
(1) Replace nuts.
(1)Replace nuts.

EXHAUST SYSTEM, INSTALLING

  1. Align exhaust system when cold.

Loosen clamping sleeve bolts (See item 18 ).

Scheme 40

Scheme 40

Press rear part of exhaust system forward -arrow- until tension at retaining loop (See item 2 ) between center and rear mufflers is -a- = 13 to 17 mm.

Install clamping sleeve horizontally.

  1. Threaded connection points toward the right.

Tighten clamping sleeve threaded connections evenly to 40 Nm.

End Pipes, Aligning

Scheme 41

Scheme 41

Align rear muffler so there is an even distance -a- and -b- between bumper cutout and tailpipes.

To align tailpipes, loosen rear muffler mounting components if necessary.

EXHAUST FLAP VACUUM DIAPHRAGM

Removing

Remove the hose on the exhaust flap vacuum diaphragm on the each rear muffler.

Scheme 42

Scheme 42: EXHAUST FLAP VACUUM DIAPHRAGM

Press the tab -1- and unclip the vacuum diaphragm in direction of arrow.

Disengage the vacuum diaphragm from the exhaust flap linkage and remove the heat shield.

Installing

Installation is in reverse order of removal.

SECONDARY AIR INJECTION (AIR) COMBINATION VALVE

Removing

If equipped, remove vacuum hose -2- to air guide hose.

Disconnect air guide hose -1- at throttle valve control module -J338-.

Disconnect mass air flow (MAF) sensor -G70- electrical connector -3-.

Remove upper section of air filter housing -arrows-.

Disconnect electrical connection to throttle valve control module -J338-.

Scheme 43

Scheme 43

Remove throttle valve control module -J338- from intake manifold -arrows-.

Remove air hose -2- and vacuum hose -1- at secondary air injection (AIR) system combination valve.

Scheme 44

Scheme 44

Remove 2 bolts -arrow- and remove combi-valve.

Installing

Installation is in reverse order of removal, note the following

Note. Replace seals.

Tightening Specifications

ComponentNm
Secondary Air Injection (AIR) Combination Valve on the Bracket or Connector9
Throttle Valve Control Module -J338- to Intake Manifold10

SECONDARY AIR INJECTION LEFT COMBINATION VALVE

Removing

Remove the throttle valve control module -J338-. Refer to Description and Operation .

Remove the hose -1- from the secondary air injection (AIR) combination valve.

Scheme 45

Scheme 45: SECONDARY AIR INJECTION LEFT COMBINATION VALVE

Disconnect vacuum hose -2-.

Remove the bolts -arrows- and lay the tube for the secondary air injection (AIR) to the side.

Remove the bolts -3- and remove the left secondary air injection (AIR) combination valve.

Note. To provide a better illustration, component location is shown from behind with engine removed.

Installing

Installation is in reverse order of removal, note the following

Note. Replace the seals

Install throttle valve control module -J338-. Refer to Description and Operation .

Tightening Specifications

ComponentNm
Secondary Air Injection (AIR) Combination Valve on the Connector9

SECONDARY AIR INJECTION RIGHT COMBINATION VALVE

Removing

Disconnect the rear vacuum hoses -1, 2, 4- from the intake manifold and free them up.

Remove wiring connection from intake manifold -arrows- and lay back with hoses connected.

Note. Ignore -3-.

Remove the bolts -arrows- and bracket -1- for the heat shield.

Scheme 46

Scheme 46

Note. To provide a better illustration, component location is shown from behind with engine removed.

Disconnect the vacuum hose -arrow-.

Scheme 47

Scheme 47

Remove the bolt -1- and remove the right combination valve for the secondary air injection (AIR) from the secondary air injection (AIR) hoses -2- and -3-.

Note. Ignore -4-.

Installing

Installation is in reverse order of removal, note the following

Note. Replace the seals Secure all hose connections with hose clamps appropriate for the model. .

Install the heat shield bracket. Refer to EXHAUST MANIFOLD COMPONENT OVERVIEW .

Tightening Specifications

ComponentNm
Secondary Air Injection (AIR) Combination Valve on the Connector9

SECONDARY AIR INJECTION SENSOR 1

Removing

Disconnect electrical connector -1-.

Scheme 48

Scheme 48: SECONDARY AIR INJECTION SENSOR 1

Remove the bolts -arrows- and remove the secondary air injection sensor 1 -G609-.

Installing

  1. Tightening specifications, refer to «SECONDARY AIR INJECTION COMPONENT OVERVIEW»(/audi/a3/8p-2004-2008/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-bub-cbra__secondary-air-injection-component-overview) .

Installation is in reverse order of removal, note the following

Note. Replace O-ring.

Tightening Specifications

ComponentNm
Secondary Air Injection Sensor 1 -G609- to Pipe3.5

SECONDARY AIR INJECTION PUMP

Removing

Disconnect secondary air hose at position indicated by -arrow-.

Free up air hose to Secondary Air Injection (AIR) pump.

Remove center noise insulation fasteners -1 to 3-.

Free up coolant hose at bottom on fan shroud.

Disconnect electrical connector -3- at secondary air injection (AIR) pump motor -V101- and free up electrical wiring.

Scheme 49

Scheme 49

On vehicles with DSG transmission, remove coolant pipe bracket -2- to transmission oil cooler.

Remove bolts -1-.

Loosen bolt -4- and remove secondary air injection (AIR) pump with bracket.

Installing

Installation is in reverse order or removal.

Tightening Specifications

ComponentNm
Secondary Air Injection (AIR) Pump to Bracket10
Secondary Air Injection (AIR) Pump BracketM610
To Cylinder BlockM820

SECONDARY AIR INJECTION (AIR) PUMP RELAY J299

Removing

If equipped, remove vacuum hose -2- to air guide hose.

Disconnect air guide hose -1- at throttle valve control module -J338-.

Disconnect mass air flow (MAF) sensor -G70- electrical connector -3-.

Remove upper section of air filter housing -arrows-.

Remove filter element.

Pull off air guide cover -1-, disengage clips sideways to do so.

Unclip air duct -2-.

Remove lower section of air filter housing -arrows-.

Vehicles with relay carrier, old version

Pull out the 6-pin relay carrier under the engine compartment E-box -arrow-.

Scheme 50

Scheme 50

Unclip 6-pin relay carrier cover -arrows-.

Scheme 51

Scheme 51

Release the retaining clips -arrows-.

Scheme 52

Scheme 52

Remove 6-pin relay carrier -arrow- from cover.

Scheme 53

Scheme 53

Remove secondary air injection (AIR) pump relay -J299- from position -R5- in 6-pin relay carrier below engine compartment E-box.

Scheme 54

Scheme 54

Vehicles with relay carrier, new version

Pull out relay carrier under engine compartment E-box -arrow-.

Scheme 55

Scheme 55

Remove secondary air injection (AIR) pump relay -J299- -1- from position in relay carrier under engine compartment E-box.

Installing

Installation is in reverse order of removal.

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 56

Scheme 56: SPECIAL TOOLS

Scheme 57

Scheme 57

Scheme 58

Scheme 58
  1. Hand Vacuum Pump VAS 6213
  2. Hose Clamps Up to 25 mm Dia.3094
  3. Ring Spanner 7-Piece Set For Oxygen Sensor 3337