Air Injection: Service and Repair

2003 Volkswagen Jetta Sedan (9M2) L4-2.0L (AZG)SECTION Service and Repair


Secondary Air Injection system components, removing and installing






Note:

- Components marked with an * are checked via the On Board Diagnostic (OBD) system

^ Components marked with ** are checked via Output Diagnostic Test mode

1. 2-pin harness connector
^ Black
2. Secondary Air Injection valve -N112- */**
^ Only engine code AEG
^ Fastened to cowl panel
3. To connection on pipe to brake booster
^ Only engine code AEG
^ Ensure it is tightly seated
4. Secondary Air Injection pump motor relay -J299- */**
^ Engine compartment left, on fuse/relay panel next to brake master Cylinder
^ Relay designation "100"
5. O-ring
^ Replace if damaged
6. Pressure hose
^ Ensure it is tightly seated
^ Press together at ends to release
7. Intake hose
^ From air filter upper section
^ Ensure it is tightly seated
^ Press together at ends to release
8. Secondary Air Injection pump motor -V101 -
^ Engine code AVH, AZG not checked via Output Diagnostic Test mode
9. 10 Nm (7 ft. lbs.)
10. Bracket
^ For Secondary Air Injection pump motor -V101
^ Attached to intake manifold lower section
11. 2-pin - harness connector
^ Black
12. 25 Nm (18 ft. lbs.)
13. Intake manifold lower section
14. To union on exhaust manifold
15. 30 Nm (22 ft. lbs.)
16. Connecting - pipe
17. 35 Nm (26 ft. lbs.)
18. Warm air collector plate
19. Gasket
^ Always replace
20. Combivalve
^ No connection on secondary air injection valve for engine code AVH, AZG
RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • You smell fuel, burning insulation, or see smoke.
  • Brakes feel soft, pull hard to one side, or make grinding noises.
  • The engine overheats, stalls repeatedly, or misfires under load.
  • You are missing required tools, torque specs, or safe lifting equipment.
  • You are not confident in the next step or safety outcome.