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Pelican Technical Article:

Secondary Air Pump Replacement

Jared Fenton

Time:

1 hour1 hr

Tab:

$200

Talent:

***

Tools:

Flathead screwdriver, 5mm Allen driver, 10mm socket

Applicable Models:

VW Jetta (1999-05)

Parts Required:

Secondary air pump

Hot Tip:

Replace torn mounting bushings if needed

Performance Gain:

Smoother running engine

Complementary Modification:

Replace coil pack and wires

The secondary or auxiliary air pump is part of the emission system and is used to inject fresh air behind the exhaust valves during the engine warm up. The air produces an oxygen rich environment that assists in after burning and helps the engine run cleaner during warm-up.

Over time, the pump is susceptible to internal failure and/or damaged mounting bushings. In this article, I'll show you how to replace the pump yourself.

Begin by removing the engine cover (See our article on Removing Engine Cover for more information).
Figure 1

Begin by removing the engine cover (See our article on Removing Engine Cover for more information). The pump is located at the front of the engine, near the battery.

Press the tabs (green arrows) inward and pull the end of the air hose leading to the air filter housing off the air pump.
Figure 2

Press the tabs (green arrows) inward and pull the end of the air hose leading to the air filter housing off the air pump.

Press the tabs (green arrows) inward and pull the end of the air hose leading to the air pump check valve housing off the air pump.
Figure 3

Press the tabs (green arrows) inward and pull the end of the air hose leading to the air pump check valve housing off the air pump.

Press the tab (green arrow) on the electrical connector and pull it off the air pump.
Figure 4

Press the tab (green arrow) on the electrical connector and pull it off the air pump. You'll also need to loosen and remove the 5mm Allen bolt (yellow arrow) holding the air pump bracket to the engine.

Now loosen and remove the two remaining 5mm Allen bolts (green arrows) holding the bracket in place.
Figure 5

Now loosen and remove the two remaining 5mm Allen bolts (green arrows) holding the bracket in place. Use a flathead screwdriver to open the clip (yellow arrow) to the bracket. Pull the bracket out of the engine bay.

Loosen and remove the three 10mm nuts holding the air pump to the bracket.
Figure 6

Loosen and remove the three 10mm nuts holding the air pump to the bracket.

It is pretty common to have one or more of the mounting bushings ripped.
Figure 7

It is pretty common to have one or more of the mounting bushings ripped. Be prepared to replace them as needed.

When fitting the new bushings, slide the end into the air pump prior to fitting the new pump into the bracket.
Figure 8

When fitting the new bushings, slide the end into the air pump prior to fitting the new pump into the bracket. At this point, you're ready to re-install the pump.

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Comments and Suggestions:
NoVA Comments: Great guide!

Would love links from related parts such as coil pack as this was hard to find on my phone.

February 4, 2017
  Followup from the Pelican Staff: Start here http://www.pelicanparts.com/Volkswagen/index-SC.htm

or

With your vehicle info, Give The Pelican Parts parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.


- Nick at Pelican Parts
 
Goonpic Comments: Thanks for this illustrated guide. It was very helpful to see how to remove this part so we could replace the coil pack on our 2003 Jetta.
January 2, 2017
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 

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Page last updated: Sun 6/25/2017 02:50:16 AM