This procedure covers the removal and replacement of the secondary air injection pump on a 2011-2014 Ford F-150 with the 3.5L EcoBoost engine, including disconnecting electrical connections, air lines, and mounting hardware.

Warnings

Tools required

Parts

• Secondary air injection pump assembly × 1 — Use OEM specification
• Air pump mounting gasket (if equipped) × 1 — Use OEM specification
• Air pump inlet filter (recommended) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and apply parking brake
2. Allow engine to cool completely (minimum 2 hours after operation)
3. Disconnect negative battery cable and wait 5 minutes for system capacitors to discharge
4. Remove engine cover by pulling upward on front and rear sections

Procedure

1. 1

   Access the secondary air pump
   From the driver's side engine bay, locate the secondary air injection pump mounted to the inner fender well near the battery. Remove any interfering air intake ducting by loosening clamps and disconnecting from air filter housing. You may need to remove the driver's side wheel well splash shield screws for better access from below.
2. 2

   Disconnect electrical connector
   Locate the electrical connector on the secondary air pump motor. Press the locking tab and pull the connector straight off the pump. Inspect the connector terminals for corrosion or damage and clean if necessary.
3. 3

   Disconnect air delivery hoses
   Using needle-nose pliers, compress the spring clamps on the outlet hose(s) connecting the pump to the air delivery system. Slide clamps away from connections and carefully remove hoses. Note the routing of hoses for reinstallation. Check hoses for cracks or deterioration and replace if damaged.
4. 4

   Disconnect inlet air filter assembly
   Locate the inlet air filter assembly connected to the pump intake. Loosen the clamp or remove fasteners securing the filter housing. Carefully disconnect the filter assembly from the pump, taking care not to allow debris to enter the pump inlet. Inspect filter element and replace if contaminated.
5. 5

   Remove pump mounting bolts
   Using a 13mm socket, remove the mounting bolts securing the secondary air pump to the bracket on the inner fender. There are typically 2-3 mounting bolts depending on the bracket design. Support the pump while removing the final bolt to prevent it from dropping.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
6. 6

   Remove secondary air pump
   Carefully maneuver the pump out of the engine bay. You may need to angle it to clear surrounding components. Inspect the mounting bracket for damage or corrosion. Clean the mounting surface with a wire brush if installing a new pump.
7. 7

   Prepare new pump for installation
   Remove the new secondary air pump from packaging and verify it matches the original unit. If a mounting gasket is used, install it on the new pump. Check that the pump rotates freely by hand (there will be some resistance from internal vanes). Do not pre-lubricate or pour oil into the pump.
8. 8

   Install new secondary air pump
   Position the new pump into the mounting bracket, aligning the mounting holes. Thread in the mounting bolts by hand to ensure proper alignment before tightening. Once all bolts are started, torque to specification in a cross-pattern to ensure even seating.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
9. 9

   Reconnect inlet air filter assembly
   Install the inlet air filter assembly (new if replacing) onto the pump inlet. Secure with clamps or fasteners, ensuring a tight seal to prevent unfiltered air from entering the system. Verify the filter element is properly seated.
10. 10

    Reconnect air delivery hoses
    Reconnect the outlet hose(s) to the pump, following the original routing noted during disassembly. Slide hoses fully onto barbed fittings until they seat against the stop. Position spring clamps over the hose connections and ensure they are properly seated in the hose groove.
11. 11

    Reconnect electrical connector
    Push the electrical connector onto the pump motor until the locking tab clicks into place. Gently tug on the connector to verify it is fully locked. Ensure wiring is routed away from hot exhaust components and sharp edges.
12. 12

    Reinstall removed components
    Reinstall any air intake ducting that was removed, ensuring all clamps are tight. If the wheel well splash shield was removed, reinstall using the original screws. Reinstall the engine cover by aligning clips and pressing down until it snaps into place. Reconnect the negative battery cable.
    Torque spec

    Cover Screws12 Nm (9 lb-ft)

Reassembly

1. Ensure all hose clamps are properly positioned and tight to prevent air leaks
2. Verify electrical connector is fully locked and wiring is secured away from moving parts
3. Double-check that all mounting bolts are torqued to specification
4. Confirm no tools or parts are left in the engine compartment

Verification

• Start the engine and allow it to idle. Listen for abnormal noises from the secondary air pump area
• Using a scan tool, verify no secondary air injection system codes are present
• During cold start, verify the secondary air pump activates (you should hear the pump running for approximately 90-180 seconds)
• Check all connections for air leaks by listening for hissing sounds while pump is operating
• Monitor the check engine light to ensure it does not illuminate during the first few drive cycles

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