This procedure covers the removal and replacement of the secondary air injection pump on a 2021-2024 Ford F-150 with the 3.5L EcoBoost V6 engine, including electrical disconnection, hose removal, and mounting hardware replacement.

Warnings

Tools required

Parts

• Secondary air injection pump assembly × 1 — Use OEM specification
• Secondary air pump inlet hose (if damaged) × 1 — Use OEM specification
• Secondary air check valve (if damaged) × 1 — Use OEM specification

Preparation

1. Ensure engine is completely cool to the touch
2. Park vehicle on level ground and engage parking brake
3. Disconnect negative battery cable and wait 2 minutes
4. Remove engine cover if equipped by pulling upward on cover clips
5. Document electrical connector orientations with photos for reference during reassembly

Procedure

1. 1

   Access the secondary air injection pump
   Remove the driver's side inner fender splash shield or access panel. Remove the plastic push clips and fasteners securing the shield. You may only need to remove the forward section for access. Pull the shield away to expose the secondary air pump mounted on the inner fender area.
2. 2

   Disconnect electrical connector
   Locate the electrical connector on the secondary air injection pump. Press the locking tab and pull the connector straight off the pump. Secure the connector away from the work area to prevent damage.
3. 3

   Remove air inlet hose
   Loosen the hose clamp securing the air inlet hose to the secondary air pump intake. Use a flat-head screwdriver or appropriate tool depending on clamp type. Twist and pull the hose off the pump inlet. Inspect the hose for cracks or damage and replace if necessary.
4. 4

   Disconnect outlet hose and check valve
   Locate the outlet hose connection from the pump to the check valve. Loosen the hose clamp and remove the hose from the pump outlet. If the check valve is integrated with the pump or requires replacement, disconnect it from the system at this time. Inspect the check valve for proper operation (should allow air flow in one direction only).
5. 5

   Remove pump mounting bolts
   Locate the mounting bolts securing the secondary air injection pump to the bracket on the inner fender. Typically there are 2-3 mounting bolts. Remove these bolts completely and set aside. Support the pump as you remove the final bolt to prevent it from falling.
   Torque spec

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

   Remove secondary air injection pump
   Carefully extract the secondary air injection pump from the engine bay. Maneuver it past any obstructions. If resistance is felt, verify all hoses and electrical connections have been disconnected. Place the old pump aside on a clean work surface.
7. 7

   Prepare new pump for installation
   Unbox the new secondary air injection pump and verify it matches the original unit. Check that all mounting points align and electrical connector is the same type. If the check valve is separate, ensure it is installed in the correct orientation (arrow indicating flow direction toward exhaust manifold).
8. 8

   Install new secondary air injection pump
   Position the new pump into the mounting location on the inner fender. Align the mounting holes with the bracket. Thread the mounting bolts by hand to prevent cross-threading. Once all bolts are started, tighten them in a star pattern to the specified torque of 31 Nm (23 lb-ft).
   Torque spec

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

   Reconnect outlet hose and check valve
   Connect the outlet hose from the pump to the check valve or secondary air system piping. Ensure the hose is seated fully onto the barbed fitting. Position the hose clamp over the hose and tighten securely. Verify the check valve arrow points toward the exhaust manifold if visible.
10. 10

    Reconnect air inlet hose
    Install the air inlet hose onto the pump intake fitting. Push the hose fully onto the barbed fitting until it bottoms out. Position the hose clamp over the connection point and tighten securely. Ensure the hose routing does not contact hot engine components or moving parts.
11. 11

    Reconnect electrical connector
    Plug the electrical connector onto the secondary air injection pump until you hear or feel a positive click. Gently tug on the connector to verify it is locked in place. Ensure the connector seal is properly seated to prevent moisture intrusion.
12. 12

    Reinstall access panels and finish
    Reinstall the inner fender splash shield or access panel. Secure all push clips and fasteners. Reinstall the engine cover if removed. Reconnect the negative battery cable. Hand-tighten the battery clamp and then snug with a wrench.

Reassembly

1. Ensure all hose clamps are tight and hoses are properly routed away from heat sources
2. Verify electrical connector is fully seated and locked
3. Double-check all mounting bolts are torqued to specification
4. Confirm no tools or parts are left in the engine bay

Verification

• Start the engine and listen for abnormal noises from the secondary air pump area during cold start
• The secondary air pump should operate for approximately 1-2 minutes during cold start, then shut off
• Check for air leaks at all hose connections by listening for hissing sounds
• Verify no check engine light illuminates related to secondary air system (P0410, P0411, P0412 codes)
• Monitor system operation through several cold start cycles over the next few days
• Inspect the work area for any fluid leaks or loose components after test drive

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