Secondary Air Injection Pump

This procedure covers the removal and replacement of the secondary air injection pump on the 2015-2020 Ford F-150 with the 5.0L Coyote V8 engine, including disconnection of air lines, electrical connectors, 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 injection hose clamps × 2 — Replace if damaged

Preparation

1. Park vehicle on level ground and engage parking brake
2. Allow engine to cool completely for at least 2 hours
3. Disconnect negative battery cable and wait 10 minutes before proceeding
4. Remove engine cover by pulling upward on front and rear tabs

Procedure

1. 1

   Access the secondary air injection pump
   Locate the secondary air injection pump on the driver side inner fender, just forward of the strut tower. The pump is a black cylindrical unit with air hoses and an electrical connector. Remove any upper engine covers or air intake ducting that may obstruct access.
2. 2

   Disconnect electrical connector
   Press the locking tab on the secondary air pump electrical connector and pull straight out to disconnect. The connector has a gray or black locking mechanism that must be depressed while pulling. Move the wiring harness aside for clearance.
3. 3

   Remove inlet air hose
   Loosen the hose clamp securing the inlet air filter hose to the pump intake using a flat blade screwdriver or 8mm socket. The inlet hose draws fresh air from the fender area. Pull the hose off the pump inlet port and move aside.
4. 4

   Remove outlet air hose
   Loosen the hose clamp on the outlet air hose that connects to the air injection manifold check valve. This is typically a spring clamp that requires squeezing with pliers or a constant-tension clamp requiring a screwdriver. Disconnect the hose from the pump outlet port.
   ℹ️The outlet hose may contain small amounts of moisture or carbon deposits, which is normal condensation from the exhaust system.
5. 5

   Remove pump mounting bolts
   Remove the three mounting bolts securing the secondary air pump to the mounting bracket on the inner fender using a 10mm or 13mm socket. Support the pump with one hand while removing the final bolt to prevent it from falling. Note the bolt locations and any spacers or washers for reinstallation.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
6. 6

   Remove secondary air pump assembly
   Carefully lift the pump assembly out of the engine bay. The pump weighs approximately 5-7 pounds. Inspect the mounting bracket for damage or cracks. Check the rubber isolation mounts if equipped for deterioration.
7. 7

   Inspect and prepare mounting area
   Clean the mounting bracket surfaces with a shop towel. Inspect the air hoses for cracks, splits, or deterioration and replace if necessary. Verify that the check valve in the air injection manifold is not clogged or stuck open by attempting to blow through it from the pump side - air should flow freely toward the manifold but not back toward the pump.
8. 8

   Install new secondary air pump
   Position the new or replacement pump onto the mounting bracket, aligning the bolt holes. Install any rubber isolation mounts or gaskets included with the new pump. Start all three mounting bolts by hand to ensure proper thread engagement before tightening.
9. 9

   Torque pump mounting bolts
   Tighten the three pump mounting bolts in a cross pattern to ensure even seating. Torque all mounting bolts to specification using a torque wrench. Verify the pump is secure and does not move when pressure is applied.
   Torque spec

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

    Connect outlet air hose
    Install the outlet air hose onto the pump discharge port, ensuring it is fully seated. The hose should slide onto the port approximately 1-1.5 inches. Secure with the hose clamp in the groove provided on the pump outlet. Tighten the clamp securely but avoid over-tightening which can damage the hose.
11. 11

    Connect inlet air hose
    Install the inlet air hose onto the pump intake port, ensuring full engagement. Secure with the hose clamp, positioning it over the hose bead. Verify the inlet air filter or screen is clean and properly installed on the remote end of the hose.
12. 12

    Reconnect electrical connector
    Push the electrical connector onto the pump connector terminals until it clicks into place. Gently tug on the connector to verify it is fully locked. Ensure the wiring harness has adequate slack and is not stretched or pinched.

Reassembly

1. Reinstall engine cover by aligning tabs and pressing down until seated
2. Reconnect negative battery cable and tighten securely
3. Verify all hose connections are tight and no tools are left in engine bay

Verification

• Start the engine from cold and listen for the secondary air pump to activate within the first 30-90 seconds of operation. The pump will make a distinct whirring or humming sound
• Check for air leaks at all hose connections while the pump is running by listening for hissing sounds
• Verify no check engine light is illuminated after 2-3 drive cycles
• Monitor for diagnostic trouble codes P0410 (Secondary Air System), P0411 (Incorrect Flow), or P0412 (Air Pump Control Circuit) using a scan tool
• Confirm pump shuts off after approximately 90-120 seconds when engine reaches operating temperature

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