Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ V.A.G 1526 A
• ◆ V.A.G 1527 B
• ◆ V.A.G 1594 A
• ◆ V.A.G 1598/31
• ◆ VAS 5051 with VAS 5051/1

Test requirement:

• ● Connect vehicle diagnosis, testing and information system VAS 5051, select "Vehicle self-diagnosis" and vehicle system "01 - Engine electronics".

Test sequence

→ Display on VAS 5051:

• ‒ Select diagnosis function "03 - Final control diagnosis" from the menu -1-
• ‒ Activate secondary air pump relay -J299.

• ‒ → Secondary air pump relay -1- should pick up and secondary air pump motor -V101 should run in intervals. (The relay is located under a cover on the left of the bulkhead).

A - If the relay does not pick up:

• ‒ Test voltage supply of secondary air pump relay .
• ‒ Test activation of secondary air pump relay => Page 26-55.

B - If the relay picks up but the secondary air pump motor does not run:

• ‒ Test voltage supply of secondary air pump motor .

Testing voltage supply of secondary air pump relay

• ‒ Switch off ignition.
• ‒ Disconnect secondary air pump relay.
• ‒ → Connect multimeter (voltage measurement range) as follows:

• ‒ Specification: approx. battery voltage

If the specification is not obtained:

• ‒ Carry out the following tests (marked with dots):

• ● → Check fuse S130 (40 A) or S131 (50A) in main fuse box/battery.
• ● Test for open circuit in wiring from battery + (terminal 30) via fuse S131 to secondary air pump relay -J299 (below cover on left side of bulkhead):

=> Current flow diagrams, Electrical fault finding and Fitting locations binder

• ‒ → Connect multimeter (voltage measurement range) as follows:

• ‒ Operate starter briefly.
• ‒ Specification: approx. battery voltage

If the specification is not obtained:

• ‒ Carry out the following tests (marked with dots):

• ● → Check fuse S243 (fuse position 43 in fuse holder).
• ● Test for open circuit in wiring from secondary air pump relay -J299 (below cover on left side of bulkhead) to fuel pump relay via fuse S243 (fuse position 43 in fuse holder):

=> Current flow diagrams, Electrical fault finding and Fitting locations binder

Testing activation of secondary air pump relay

• ‒ Switch off ignition.
• ‒ Disconnect secondary air pump relay.
• ‒ → Connect voltage tester V.A.G 1527 B as follows:

→ Display on VAS 5051:

• ‒ Select diagnosis function "03 - Final control diagnosis" from the menu -1-
• ‒ Activate secondary air pump relay -J299.
• ‒ The LED should flash.

If the LED does not flash:

• ‒ Switch off ignition.
• ‒ → Connect test box V.A.G 1598/31 to wiring harness connectors. The engine control unit itself does not need to be connected to the test box. Connect earth clamp on test box to earth -arrow-.

=> Motronic injection and ignition system; Repair group 24

• ‒ → Test for open circuit and short to positive or earth in the following wiring connections:

• ‒ Rectify any open/short circuit as necessary.

If no fault is found:

• ‒ Fit a new secondary air pump relay -J299.

Testing voltage supply to secondary air pump motor

• ‒ → Remove noise insulation centre panel -arrows-.

• ‒ → Unplug connector -1- from secondary air pump motor -V101.

• ‒ → Connect voltage tester V.A.G 1527 B between contacts 1 and 2.

→ Display on VAS 5051:

• ‒ Select diagnosis function "03 - Final control diagnosis" from the menu -1-
• ‒ Activate secondary air pump relay -J299.
• ‒ The LED should flash.

If the LED does not flash:

• ‒ Carry out the following tests (marked with dots):

• ● Test for open circuit in wiring from connector on secondary air pump motor -V101 to secondary air pump relay -J299 (in relay carrier below cover on left side of bulkhead):

=> Current flow diagrams, Electrical fault finding and Fitting locations binder

• ● Test for open circuit in wiring from contact 1 of connector to earth:

=> Current flow diagrams, Electrical fault finding and Fitting locations binder

If no fault is found:

• ‒ Replace secondary air pump => Page 26-67.