This procedure covers the removal and replacement of the secondary air injection pump on a 2011-2014 Ford F-150 with the 5.0L Coyote V8 engine.

Warnings

Tools required

Parts

• Secondary air injection pump assembly × 1 — Use OEM specification
• Air pump mounting gasket × 1 — Use OEM specification
• Air pump inlet hose (if damaged) × 1 — Inspect before ordering

Preparation

1. Ensure engine is completely cool to the touch
2. Disconnect negative battery cable and wait 5 minutes for system capacitors to discharge
3. Raise and safely support vehicle on jack stands or lift to access underside
4. Remove engine splash shield/skid plate if equipped (multiple 10mm bolts)

Procedure

1. 1

   Locate and access secondary air injection pump
   The secondary air pump is mounted on the driver's side of the engine bay, low near the frame rail. From underneath, identify the pump assembly which is a black cylindrical unit approximately 6 inches in diameter with electrical connector and air hoses attached.
2. 2

   Disconnect electrical connector
   Press the tab on the electrical connector attached to the air pump and pull straight away from the pump. The connector may be stiff due to age and weather exposure. If necessary, spray electrical contact cleaner and work the connector gently to avoid breaking the tab.
3. 3

   Remove air inlet hose
   Loosen the hose clamp securing the inlet air filter hose to the pump intake using an 8mm socket or flat blade screwdriver. Twist and pull the hose off the pump inlet port. Inspect the hose for cracks or deterioration and replace if necessary.
4. 4

   Disconnect air outlet hose
   Locate the outlet hose on the opposite side of the pump. This connects to the air injection manifold via a rubber coupling. Loosen the hose clamp with an 8mm socket and separate the hose from the pump outlet. Note the orientation for reassembly.
5. 5

   Remove pump heat shield
   The heat shield is secured by multiple bolts around the pump assembly. Remove all heat shield mounting bolts using a 10mm socket. Keep track of bolt locations as some may be different lengths. Remove the heat shield and set aside.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
6. 6

   Remove pump mounting bolts
   The secondary air pump is secured to its bracket with three mounting bolts accessible from below. Using a 13mm socket with extension, remove all three mounting bolts while supporting the pump weight. The upper rear bolt may require a longer extension to access.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
7. 7

   Remove pump assembly
   Carefully lower the pump assembly down and maneuver it out from between the frame rail and engine block. The pump is heavy (approximately 8-10 lbs) and may require tilting at an angle to clear surrounding components. Work slowly to avoid damaging nearby wiring or hoses.
8. 8

   Clean mounting surfaces
   With the pump removed, use a wire brush to clean the mounting bracket surfaces and bolt holes. Remove any corrosion, dirt, or old gasket material. Use compressed air or a shop vacuum to clear debris from the mounting area. Inspect the mounting bracket for cracks or damage.
9. 9

   Install new pump assembly
   Position the new secondary air pump assembly with fresh mounting gasket in place. Maneuver the pump into position between the frame rail and engine block, aligning the mounting holes with the bracket. Thread all three mounting bolts by hand first to ensure proper alignment before tightening.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
10. 10

    Torque mounting bolts
    Using a torque wrench and 13mm socket, tighten the three pump mounting bolts to specification in a star pattern (if applicable) or alternating pattern to ensure even seating. Verify all bolts are secure and the pump does not move when pressure is applied.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
11. 11

    Reinstall heat shield
    Position the heat shield over the pump assembly, aligning all mounting holes. Install all heat shield bolts and tighten to specification using a 10mm socket and torque wrench. Ensure the shield does not contact any hoses or wiring.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)
12. 12

    Reconnect air outlet hose
    Slide the air outlet hose onto the pump outlet port, ensuring it is fully seated. Position the hose clamp over the connection point and tighten securely with an 8mm socket. Verify the hose routing matches the original configuration and does not contact hot exhaust components.
13. 13

    Reconnect air inlet hose and electrical connector
    Install the inlet air filter hose onto the pump intake port, ensuring full insertion. Tighten the hose clamp securely. Connect the electrical connector to the pump, pushing firmly until it clicks into place. Tug gently to verify proper locking engagement.
14. 14

    Reinstall underbody components
    Reinstall the engine splash shield or skid plate using all original mounting bolts. Ensure all fasteners are tight. Reconnect the negative battery cable at the battery terminal and tighten securely.

Reassembly

1. Double-check all hose connections are secure and clamps are tight
2. Verify electrical connector is fully engaged with audible click
3. Ensure no tools or parts are left in engine bay before starting engine
4. Confirm heat shield is properly positioned and does not contact moving parts

Verification

• Start the engine from cold and listen for secondary air pump operation. The pump should activate within 30 seconds of cold start and run for approximately 90-120 seconds
• Listen for abnormal noises from the pump area. The pump will make a distinct humming or whirring sound when operating normally
• Check for air leaks at all hose connections by listening for hissing sounds while pump is running
• Verify no check engine light appears on instrument cluster. If codes are present, use scan tool to verify system operation
• After engine warms up and pump stops, verify all connections remain dry and secure with no leaks

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