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Pelican Technical Article:

Secondary Air Hose Replacement

Jared Fenton

Time:

1 hour1 hr

Tab:

$25 to $80

Talent:

***

Tools:

Your fingers

Applicable Models:

Jetta MkIV 2.0L (1998-05)

Parts Required:

Secondary air hoses

Hot Tip:

Take your time releasing the hoses. They can be tricky.

Performance Gain:

Smoother, cleaner running engine

Complementary Modification:

Replace air filter

The plastic secondary air hoses on the Mk4 Jetta 2.0 are prone to cracking and breaking over time. This can present a number of problems when getting the car to pass emissions tests. Often times, leaking hoses can trigger a check engine light. It's a good idea to check the system with a diagnostic scanner to read the codes. In this article I'll show you how to change the hoses yourself.

Squeeze the tabs (green arrows) on the larger secondary air hose and pull it off the secondary air pump.
Figure 1

Squeeze the tabs (green arrows) on the larger secondary air hose and pull it off the secondary air pump. This may take a little effort.

Now squeeze the tabs (green arrows) where the hose connects to the air filter housing as shown here.
Figure 2

Now squeeze the tabs (green arrows) where the hose connects to the air filter housing as shown here. Pull the old hose off. The new hose simply plugs into the connections at the pump and the air filter housing.

Squeeze the tabs (green arrows) on the smaller secondary air hose and pull it off the diverter valve.
Figure 3

Squeeze the tabs (green arrows) on the smaller secondary air hose and pull it off the diverter valve. As before, this may take a bit of effort to do. Note that the throttle body has been removed for purposes of clarity. You'll have to feel for it when you remove this side.

In the center of the hose is a small tab (green arrows) that keeps the hose in place.
Figure 4

In the center of the hose is a small tab (green arrows) that keeps the hose in place. Disconnect the tab and pull the hose off. The new hose will have a tab that fits in place. Also note how the hose broke in the middle. It appears that they tried to make a short term repair with some PVC pipe and electrical tape.

Figure 5

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