Removing and installing parts of the secondary air system — VW
Removing and installing parts of the secondary air system on VW: factory workshop procedure for engines AAA, ABA, ABV, AEH.
Workshop procedure for VW — the factory write-up, straight from real workshop data.
📐 23 workshop diagrams for AAA
Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.
📋 Procedure
ℹ️ Torque figures below come verbatim from workshop data — always cross-check against your vehicle's factory manual before final tightening.
Notes:
Components marked with an * are checked by the self-diagnosis:
=> Repair Group 01; Fault memory; Interrogating and erasing fault memory
5-Cyl. Injection Engine (4 Valve), Mechanics
Fault memory
Interrogating and erasing fault memory
Components marked with ** are checked by the final control diagnosis:
=> Repair group 01; Final control diagnosis; Performing final control diagnosis
5-Cyl. Injection Engine (4 Valve), Mechanics
Final control diagnosis
Performing final control diagnosis
Secondary air pump relay (J299)** =>Page
26-22
, Fig.
1
Intake manifold - upper part
Vacuum positioning element
For intake manifold change-over
To intake manifold
To fuel pressure regulator
O-ring
Renew if damaged
Combi-valve
Checking =>Page
26-31
Gasket
Renew
Air channel
In cylinder head
Gasket
Renew
Note fitting position
8 Nm
Connection
For combi-valve and coolant hose
Coolant hose connection diagram =>Page
19-11
5 Nm
Pressure hose
Ensure seated tightly
Press together at front to release
Connection
Secondary air pump motor (V101)**
Checking =>Page
26-27
Removing and installing =>Page
26-30
Bracket
For secondary air pump motor
Secured in front of the reservoir for the power steering system
Connector
Black, 2-pin
For secondary air pump motor
Retaining clip
Air cleaner
If soiled, clean
Intake hose
Ensure seated tightly
Press together at front to release
Connector
Black, 2-pin
Before pulling off, mark component to which it belongs
Non-return valve
Note installation position
White connector faces towards secondary air inlet valve (N112)/intake manifold change-over valve (N156)
Intake manifold change-over valve (N156)*/**
The valve will be activated from the engine control unit (pulsed)
Secondary air inlet valve (N112)*/**
The valve will be activated from the engine control unit (pulsed)
Vacuum reservoir
Clipped into bracket, item
27
, and secured with bolt
13 Nm
Bracket
For vacuum reservoir, intake manifold change-over valve and secondary air inlet valve
Fig.1
Secondary air pump relay (J299) -arrow-
Notes:
If tools are necessary to pull relays or control units out of the relay plate, first disconnect battery earth strap.
Before disconnecting battery earth strap obtain code for radios with anti-theft coding.
TorqFix answers live for your specific car — tell it the engine code and it serves the matching sequence, torque figures and wiring for that exact variant.
Ask about my car →Other VW procedures
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- Dismantling and assembling air cleaner
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- Removing and installing camshafts – VW Passat B6 · 39 torque figures
- Removing and installing coolant pump · 53 torque figures
Who makes these pages, and how
TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.
The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.
Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.
Seen a figure that does not match your manual? Write to us — we correct it and note when. support@torqfix.com
The story behind TorqFix →Workshop data on this page last updated 20 Sep 2026.