exhaust

Secondary Air Injection Pump

for 2016 Ford F-150 3.5L V6 EcoBoost · RWD

Editorial review:Chris Hackleman — Master Technician · 20+ years

Difficulty

Moderate

Time

1.8 h

Tools

Steps

✓Expert-verified. Personally reviewed and approved by OLP's master technicians (Chris Hackleman — 20+ years each). Always follow the vehicle's factory service information and torque specs.

This procedure covers the removal and replacement of the secondary air injection pump on the 2015-2020 Ford F-150 with the 3.5L EcoBoost V6 engine.

Warnings

⚠Allow engine to cool completely before beginning work. Exhaust components may remain hot for extended periods.

⚠The secondary air injection pump operates during cold starts. Do not attempt to disconnect electrical connectors while the system is active.

ℹ️The secondary air injection pump is located on the passenger side of the engine compartment near the fender well.

Tools required

10mm socket and ratchetEssential

13mm socket and ratchetEssential

15mm socket and ratchetEssential

Torque wrenchEssential

Socket extension setEssential

Flathead screwdriver

Panel trim removal tools

Wire brush

Anti-seize compoundEssential

Flashlight or work light

As an Amazon Associate and Autel/ANCEL partner, OLP earns from qualifying purchases — how we link. This never changes the specs we publish.

Parts

Secondary air injection pump assembly × 1 — Use OEM specification
Secondary air pump mounting gasket × 1 — Use OEM specification
Secondary air injection hose (if damaged) × 1 — Use OEM specification

As an Amazon Associate and Autel/ANCEL partner, OLP earns from qualifying purchases — how we link. This never changes the specs we publish.

Preparation

Ensure engine is completely cool to the touch
Park vehicle on level surface and engage parking brake
Disconnect negative battery terminal and wait 2 minutes
Remove engine cover by lifting upward on retaining clips

Procedure

1
Access the secondary air injection pump
Locate the secondary air injection pump on the passenger side of the engine bay near the inner fender. It is mounted to a bracket with the air hoses and electrical connector attached. You may need to remove any air intake ducting or components obstructing access.
2
Disconnect electrical connector
Press the locking tab on the secondary air injection pump electrical connector and pull away from the pump. Ensure the connector does not hang against hot engine components.
3
Remove heat shield if equipped
If a heat shield covers the pump or mounting area, remove the retaining bolts using a 10mm socket. Set the heat shield aside.
4
Disconnect inlet air hose
Loosen the hose clamp on the inlet air hose (typically from the air filter housing) using a flathead screwdriver or appropriate tool. Slide the clamp back and remove the hose from the pump inlet. Inspect the hose for cracks or damage.
5
Disconnect outlet air hoses
Remove the outlet hose(s) that connect from the pump to the exhaust manifolds. Loosen hose clamps or disconnect quick-connect fittings as applicable. Note the routing of hoses for reinstallation.
6
Remove pump mounting bolts
Using a 13mm or 15mm socket (verify size on your specific pump), remove the mounting bolts securing the secondary air injection pump to its bracket. Support the pump as you remove the final bolt.
7
Remove secondary air injection pump
Carefully maneuver the pump assembly out of the engine bay. It may be necessary to angle the pump to clear surrounding components. Avoid damaging any wiring harnesses or hoses during removal.
8
Inspect mounting bracket and gasket
With the pump removed, inspect the mounting bracket for cracks or damage. Remove the old gasket material from the mounting surface using a wire brush or scraper. Clean the mounting surface thoroughly.
9
Install new secondary air injection pump
Position the new gasket on the mounting bracket. Align the new secondary air injection pump with the mounting holes and insert the mounting bolts. Thread bolts by hand initially to ensure proper alignment.
10
Torque mounting bolts
Using a torque wrench, tighten the pump mounting bolts to 31.0 Nm (23.0 lb-ft) in a cross pattern to ensure even seating of the pump.
11
Reconnect outlet air hoses
Attach the outlet hose(s) to the pump, routing them in the same configuration as removed. Secure all hose clamps or quick-connect fittings. Ensure connections are tight and properly seated.
12
Reconnect inlet air hose
Attach the inlet air hose to the pump inlet and secure with the hose clamp. Verify the hose is fully seated on the pump inlet before tightening the clamp.
13
Reinstall heat shield and electrical connector
If removed, reinstall the heat shield and torque bolts to 10.0 Nm (7.0 lb-ft). Reconnect the electrical connector to the secondary air injection pump, ensuring it clicks into place securely.
14
Reinstall engine cover and battery connection
Reinstall any air intake ducting or components that were removed for access. Replace the engine cover by aligning the clips and pressing down firmly. Reconnect the negative battery terminal.

Reassembly

Double-check all hose connections and clamps for security
Ensure the electrical connector is fully engaged with no exposed pins
Verify no tools or parts have been left in the engine bay

Verification

Start the engine from cold and listen for the secondary air injection pump to activate (typically runs for 1-2 minutes during cold start)
Listen for any unusual hissing or air leak sounds from the pump or hose connections
Check for diagnostic trouble codes using an OBD-II scanner; clear any codes that may have been set during the repair
Verify the check engine light remains off after a complete cold start cycle
Inspect all connections visually for proper installation and no movement