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
- 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.
- 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).
- The motronic control module -J220- controls the secondary air pump motor -V101- to the secondary air pump relay -J299-.
Scheme 9
- Bracket For exhaust system
- Retaining Loop Replace if damaged
- 23 Nm
- 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)
- Retaining Loop Replace if damaged
- 23 Nm
- Bracket for Exhaust System
- 25 Nm
- Suspended Mount Replace if damaged
- 40 Nm Replace
- Seals Replace
- Front Exhaust Pipe Support
- 25 Nm
- 40 Nm
- 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)
- 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)
- 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)
- 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
- 40 Nm Replace
- 23 Nm
- Suspended Mount Replace if damaged
- 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)
- Retaining Loop Replace if damaged
- 23 Nm
- Bracket for Exhaust System
Scheme 10
Install clamping sleeve horizontally.
- Threaded connection points toward the right.
Scheme 11
- 23 Nm Replace
- 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)
- Gasket Replace
- Gasket With heat shield Replace
- Heat Shield
- 10 Nm
- Bracket Depending on the version, riveted with a heat shield
- 20 Nm
- Bracket
- 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
- 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)
- Rubber Bushing
- 9 Nm
- Bracket For Secondary Air Injection (AIR) pump motor -V101
- 9 Nm
- 9 Nm
- Secondary Air Hose Check for secure seat
- Gasket Replace
- Connection For coolant and secondary air injection (AIR) combi-valve
- 9 Nm
- 9 Nm
- Gasket Replace
- 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)
- O-ring Replace if damaged
- Secondary Air Hose Check for secure seat
- O-ring Replace if damaged
- O-ring Replace if damaged
- Connecting Piece To air filter
- Air Filter Housing Clean if contaminated
Scheme 13
- 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)
- Rubber Bushing
- 9 Nm
- Bracket For secondary air injection (AIR) pump motor -V101
- 9 Nm
- 9 Nm
- Hose Check for secure seat
- Vacuum Hoses
- Secondary Air Injection (AIR) Solenoid Valve 2 -N320- Component location (Scheme 16)
- Vacuum Hoses
- Secondary Air Injection (AIR) Solenoid Valve -N112- Component location (Scheme 16)
- Gasket Replace
- Connection For coolant and left secondary air injection (AIR) combination valve
- 9 Nm
- Gasket Replace
- Connection For right Secondary Air Injection (AIR) combination valve
- 9 Nm
- Hose Check for secure seat
- 9 Nm
- Connection For right Secondary Air Injection (AIR) combination valve
- 9 Nm
- Gasket Replace
- 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)
- Gasket Replace
- 9 Nm
- Angle Piece For right Secondary Air Injection (AIR) combination valve
- Hose Check for secure seat
- 9 Nm
- Pipe
- Gasket Replace
- 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)
- Gasket Replace
- 9 Nm
- O-ring Replace if damaged
- 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)
- 3.5 Nm
- O-ring Replace
- Pipe
- 9 Nm
- O-ring Replace if damaged
- O-ring Replace if damaged
- Connecting Piece To air filter
- Air Filter Housing Clean if soiled
Scheme 14
- In E-box, engine compartment.
3 - Secondary Air Injection (AIR) pump relay -J299
Scheme 15
- In E-box, engine compartment.
F - 40 A secondary air injection (AIR) pump motor -V101- fuse
Scheme 16
- On vacuum reservoir at front on the intake manifold.
- Secondary air injection (AIR) solenoid valve -N112
- Secondary air injection (AIR) solenoid valve 2 -N320- - engine code CBRA only
FASTENER TIGHTENING SPECIFICATIONS
| Component | Bolt Size | Nm |
|---|---|---|
| Angle Piece for Right Secondary Air Injection (AIR) Combination Valve | 9 | |
| Bracket (5) | 20 | |
| Bracket (6) | 10 | |
| Bracket for Exhaust System | 23 | |
| Bracket for Secondary Air Injection (AIR) Pump Motor | ||
| Bolt | 9 | |
| Nut | 9 | |
| Clamping Sleeve, Nut | 40 (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 CBRA | 9 | |
| Exhaust Manifold, Nut | 23 (2) | |
| Exhaust Manifold Heat Shield to Cylinder Head | 20 | |
| Front Exhaust Pipe Support | ||
| 25 (1) | ||
| 40 (1) | ||
| Front Exhaust Pipe With Catalytic Converters and Front Muffler, Nut | 40 (2) | |
| Heat Shield | 10 | |
| Oxygen Sensor in Front Exhaust Pipe | 55 | |
| Pipe | 9 | |
| Secondary Air Injection (AIR) Combination Valve on the Bracket or Connector | 9 | |
| Secondary Air Injection (AIR) Pump Bracket | M6 | 10 |
| To Cylinder Block | M8 | 20 |
| Secondary Air Injection Sensor 1 to Pipe | 3.5 | |
| Suspended Mount (4) | 25 (2) | |
| Suspended Mount (3) | 23 (3) | |
| Throttle Valve Control Module to Intake Manifold | 10 | |
| (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
- Hand Vacuum Pump VAS 6213
Test Sequence
- Vacuum lines and hose connections free of leaks.
- Vacuum lines not plugged.
Disconnect hose on vacuum diaphragm for exhaust flap at rear muffler.
Connect hand vacuum pump to vacuum diaphragm.
Scheme 17
Generate vacuum using hand vacuum pump.
Scheme 18
- Linkage must move upward.
Vent the hand vacuum pump.
- 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
- Vacuum lines and hose connections free of leaks.
- 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
Blow lightly into assisting hose by mouth, do not use compressed air.
- 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.
- 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
- Hose Clamps Up to 25 mm Dia.3094 for the left Secondary Air Injection (AIR) combination valve
- Hand Vacuum Pump VAS 6213
Procedure
- Vacuum lines and hose connections free of leaks.
- Vacuum lines not plugged.
Left secondary air injection (AIR) combi-valve
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
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
Disconnect the vacuum hose from the secondary air injection (AIR) combination valve.
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).
- 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.
- 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
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.
- 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.
- 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
- Ring Spanner 7-Piece Set For Oxygen Sensor 3337
Removing
If equipped, remove vacuum hose -2- to air guide hose.
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
Unclip air duct -2-.
Remove lower section of air filter housing -arrows-.
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
Free up electrical wiring to oxygen sensors.
Remove heated oxygen sensor (HO2S) 2 -G108- -1- and heated oxygen sensor (HO2S) -G39- -2-.
Scheme 29
Remove bolts -1- and -3- and remove front exhaust pipe support -2-.
Scheme 30
Remove front exhaust pipe nuts accessible from top from exhaust manifolds -arrows-.
Scheme 31
Remove center noise insulation fasteners -1 to 3-.
Scheme 32
Remove right noise insulation fasteners -1 to 3-.
Scheme 33
Remove the right vehicle underbody cover -arrows-.
Scheme 34
Disconnect electrical connectors -1- and -2- at right of vehicle floor.
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
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
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
| Component | Nm |
|---|---|
| Front Exhaust Pipe to Exhaust Manifold | 40 (1) |
| Catalytic Converter to Front Exhaust Pipe | 23 (1) |
| Oxygen Sensor in Front Exhaust Pipe | 55 |
| Exhaust System Bracket to Subframe | 23 |
| (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
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
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
| Component | Nm |
|---|---|
| Exhaust Manifold to Cylinder Head | 23 (1) |
| Front Exhaust Pipe to Exhaust Manifold | 40 (1) |
| Exhaust Manifold Heat Shield to Cylinder Head | 20 |
| (1) Replace nuts. | |
| (1) | Replace nuts. |
EXHAUST SYSTEM, INSTALLING
- Align exhaust system when cold.
Loosen clamping sleeve bolts (See item 18 ).
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.
- Threaded connection points toward the right.
Tighten clamping sleeve threaded connections evenly to 40 Nm.
End Pipes, Aligning
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
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
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
Remove 2 bolts -arrow- and remove combi-valve.
Installing
Installation is in reverse order of removal, note the following
Note. Replace seals.
Tightening Specifications
| Component | Nm |
|---|---|
| Secondary Air Injection (AIR) Combination Valve on the Bracket or Connector | 9 |
| Throttle Valve Control Module -J338- to Intake Manifold | 10 |
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
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
| Component | Nm |
|---|---|
| Secondary Air Injection (AIR) Combination Valve on the Connector | 9 |
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
Note. To provide a better illustration, component location is shown from behind with engine removed.
Disconnect the vacuum hose -arrow-.
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
| Component | Nm |
|---|---|
| Secondary Air Injection (AIR) Combination Valve on the Connector | 9 |
SECONDARY AIR INJECTION SENSOR 1
Removing
Disconnect electrical connector -1-.
Scheme 48
Remove the bolts -arrows- and remove the secondary air injection sensor 1 -G609-.
Installing
- 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
| Component | Nm |
|---|---|
| Secondary Air Injection Sensor 1 -G609- to Pipe | 3.5 |
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
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
| Component | Nm | |
|---|---|---|
| Secondary Air Injection (AIR) Pump to Bracket | 10 | |
| Secondary Air Injection (AIR) Pump Bracket | M6 | 10 |
| To Cylinder Block | M8 | 20 |
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
Unclip 6-pin relay carrier cover -arrows-.
Scheme 51
Release the retaining clips -arrows-.
Scheme 52
Remove 6-pin relay carrier -arrow- from cover.
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
Vehicles with relay carrier, new version
Pull out relay carrier under engine compartment E-box -arrow-.
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 57
Scheme 58
- Hand Vacuum Pump VAS 6213
- Hose Clamps Up to 25 mm Dia.3094
- Ring Spanner 7-Piece Set For Oxygen Sensor 3337
See also:
• Removal and Installation
• EXHAUST SYSTEM, INSTALLING
• FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER
• EXHAUST MANIFOLD
• SECONDARY AIR INJECTION PUMP
• SECONDARY INJECTION COMBINATION VALVE, CHECKING FOR FUNCTION AND LEAKS
• SECONDARY AIR INJECTION (AIR) COMBINATION VALVE
• SECONDARY INJECTION COMBINATION VALVES, CHECKING FOR FUNCTION AND LEAKS
• SECONDARY AIR INJECTION RIGHT COMBINATION VALVE
• SECONDARY AIR INJECTION LEFT COMBINATION VALVE
• SECONDARY AIR INJECTION SENSOR 1
• EXHAUST SYSTEM COMPONENT OVERVIEW
• SECONDARY AIR INJECTION COMPONENT OVERVIEW