How-To: Repair a Air Injection Pump

[pepino68]

audiomechanic and downtown turbo thanks.was little tricky getting it out and in but the mod was easy.
by the pool chillin b4 it goes back to work,sorry about the big pix

[scarabY2k]

DUDE!!!

3 words..

VSO image resizer. <<<< CLICK. It's freewrare and it works great!

That pic is eatin up a lot of real estate

[tihol]

What is the harm of removing the pump altogether?

[timf]

Great write up and the pictures really help :-)
I'm trying to get my 2.0L 2002 Beetle through CA smog.

It has no CEL issues, but it fails the readiness for SAIP with "failure or not complete".

The pump runs when the engine is cold and seems to suck air ok. The output from the SAIP goes directly to a valve on the rear of the engine (combi or EGR) but is not vacuum controlled - I'm a puzzled by this.

The hoses all seem to be in good shape.

I did find a broken vacuum hose between the manifold and fuel pressure regulator - this cleared an O2 heating readiness issue but not the SAIP.

maybe it just takes a bunch of cold starts to clear this last readiness code or maybe there's something else like the SAIP not producing enough air or the valve is stuck ?

My SAIP seems to be a one piece job.

Any ideas ?

[Droid]

if you want to get a nice look, use some socket head or button head cap screws adn nylock nuts....

[Beetle1.8turbo]

i just got a new pump but mine has 3 screw to mount it and the new one dont what did i do wrong?

[esse10]

Great DIY write up , GOOD JOB Audiomechanic. I will look at mine asap.

[lil.smartie]

@ Beetle1.8turbo

There are a few part numbers. Mine also needed the 3 mounts on the pump and I've found that either 078 906 601 m or 06A959253 (but NOT with a B on the end) look to be the correct one for my car which is a 2000 APH 1.8t, I think it changes to the one with the B in 2001 but most Euro parts go on actual build date of the car, the US change 'model year' in October of the year before which may catch people out.

I hope that helps someone else, I was sent the wrong one by a supplier despite checking that it was for a 2000 APH so I've spent a few hours checking. The 2 part numbers above both cross reference to the same part in Pierburg catalogue.

Kate

[Beetle_NZ]

mine has no revits and could feel that air coming out wer tha tube and the pump connects. can i fix this or need a new pump? i could hear the jet plane sound on this area and somewhere below the battery..somwere there i think..

[IndyTom]

Originally Posted by Beetle_NZ

mine has no revits and could feel that air coming out wer tha tube and the pump connects. can i fix this or need a new pump? i could hear the jet plane sound on this area and somewhere below the battery..somwere there i think..

There is no way to fix the pumps that have no rivits. I think they must have switched to the rivetless design sometime late in 2001 since it seems none of the 2002 on up have the rivits anymore. If your pump is bad it will need to be replaced.

Volkswagen New Beetle 1.8T > Search > Pump > ES#1876813 Secondary Air Injection Pump - 06A959253B

Seems all the new pumps or aftermarket pumps don't have rivits either.

[Beetle_NZ]

but my bug is 2002 model..how come cant find any revits? do you think it was already change by the previous owner?

[IndyTom]

Originally Posted by Beetle_NZ

but my bug is 2002 model..how come cant find any revits? do you think it was already change by the previous owner?

Read my above post again. They changed the design sometime in 2001 so none of the 2002 on up Beetle's have the old rivet design pumps. Yours is a 2002 so you already have the new and improved NON-rivet design.
Only way to fix it is to replace it.

[Beetle_NZ]

Indytom just opened my engine cover and found out that the tube lines were the air leeks was not totally place properly in the SAP and loose. When I push it in, it click and locked. Now it wont make a jet engine sound no more!! yepey..thanks org!!

[jetta02awp]

Best DIY! Saved me from buying a new sai! And got rid of the cel!

Sent from my PC36100 using AutoGuide.com App

[dansbor]

Well, thanks for the compliment!

This might be a good preventive measure as well since, according to my mechanical Herr Schmidt, the rivets tend to give the bottom of the pump and therefore can take in water and freeze. No bueno.

[Chef Nails]

So after a little searching I found this:

VW AUDI SECONDARY AIR PUMP 06A959253B 2000-2008 NEW | eBay

Not too bad considering the alternatives - although I am still going to remove mine and see if I can somehow repair it before dropping the money on a new one.

[IndyTom]

Originally Posted by Chef Nails

So after a little searching I found this:

VW AUDI SECONDARY AIR PUMP 06A959253B 2000-2008 NEW | eBay

Not too bad considering the alternatives - although I am still going to remove mine and see if I can somehow repair it before dropping the money on a new one.

Here is one cheaper but ECS is always back ordered on the cheapo pump. I guess everybody wants one.

Volkswagen New Beetle 1.8T > Search > Air Pump > ES#2532875 Secondary Air Injection Pump - 06A959253E

You can try and see if you can reseal your pump with some silicone or JB Weld? Might be worth a shot.

[dansbor]

This can be a good preventive measure because, according to my mechanic Herr Schmidt, rivets tend to give the bottom of the pump and therefore can take in water and freeze. There is no bueno.