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

Fitting location=>Fitting locations overview

=> Motronic injection and ignition system; Repair group 24; Servicing Motronic injection system; Fitting locations overview

Test sequence

• ‒ Start final control diagnosis and select secondary air pump relay -J299

=> Motronic injection and ignition system; Repair group 01; Final control diagnosis

• ‒ → The secondary air pump relay should pick up and secondary air pump motor -V101 should run intermittently. (Relay is located in relay position 2 in 3-way relay carrier in electronics box on left side of plenum chamber).

A - If the relay does not pick up:

• ‒ Test voltage supply of secondary air pump relay .
• ‒ Test activation of secondary air pump relay => Page 26-69.

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):

• ● → Test fuse No. S130 (40 A) in 3-way relay carrier in electronics box, in plenum chamber, socket position 7
• ● Test for open circuit in wiring from battery + (terminal 30) via fuse No. S130 to secondary air pump relay -J299 (located in socket position 2 of 3-way relay carrier in electronics box in plenum chamber.)

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

• ‒ 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):

• ● → Test fuse No. S234 (in fuse box, socket 34).
• ● Test for open circuit in wiring from fuel pump relay to secondary air pump relay -J299 (located in 3-way relay carrier in electronics box in plenum chamber) via fuse No. S234 (socket 34 in fuse box):

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

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:

• ‒ Start final control diagnosis and select secondary air pump relay -J299.

=> Motronic injection and ignition system; Repair group 01; Final control diagnosis

• ‒ The LED should flash.

If the LED does not flash:

• ‒ Switch off ignition.

• ‒ Connect test box V.A.G 1598/31 to wiring harness for engine control unit.Do notconnect to the engine control unit itself.

=> Motronic ignition and injection system; Repair group 24; Servicing Motronic injection system; Testing fuel pump relay and activation

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

• ‒ 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

• ‒ Unplug connector from secondary air pump motor -V101.
• ‒ Connect voltage tester V.A.G 1527 B between contacts 1 and 2.
• ‒ Start final control diagnosis and select secondary air pump relay -J299.

=> Motronic injection and ignition system; Repair group 01; Final control diagnosis

• ‒ 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 for secondary air pump motor -V101 to secondary air pump relay -J299 (located in 3-way relay carrier in electronics box in plenum chamber, socket position 2)

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

• ● Test for open circuit in wiring from connector on motor -V101 to earth connection 1 in engine compartment wiring harness:

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

If no fault is found:

• ‒ Renew secondary air pump motor -V101.