This procedure covers the removal and replacement of the secondary air injection pump on the 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine, including disconnection of electrical connections, air hoses, and mounting hardware.

Warnings

Tools required

Parts

• Secondary air injection pump assembly × 1 — Use OEM specification
• Air pump inlet hose gasket × 1 — Use OEM specification
• Air pump outlet gasket × 1 — Use OEM specification

Preparation

1. Ensure engine is completely cool to the touch
2. Park vehicle on level surface and engage parking brake
3. Disconnect negative battery terminal and wait 3 minutes
4. Remove engine cover by pulling upward on plastic clips
5. Locate secondary air injection pump on driver's side of engine bay, mounted to inner fender well

Procedure

1. 1

   Disconnect electrical connector
   Press the release tab on the electrical connector attached to the secondary air injection pump and pull straight out to disconnect. Move wiring harness aside to provide clearance.
2. 2

   Remove air inlet hose
   Locate the air inlet hose connected to the pump inlet (draws fresh air from air filter housing). Use flathead screwdriver to loosen hose clamp, then twist and pull hose off pump inlet fitting. Inspect hose for cracks or deterioration.
3. 3

   Disconnect air outlet check valve
   Locate the metal air injection line connected to pump outlet with check valve assembly. Remove the two flange bolts securing the check valve to the pump using 12mm socket. Separate check valve from pump and support line to prevent stress on connections.
   ℹ️Note the orientation of check valve - arrow on valve body must point away from pump toward exhaust manifold on reinstallation.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
4. 4

   Remove pump bracket mounting bolts
   Remove the three mounting bolts securing the secondary air pump bracket to the inner fender well using 14mm socket. Support pump weight while removing final bolt to prevent it from falling.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
5. 5

   Remove secondary air pump
   Carefully maneuver pump assembly out of engine bay, feeding wiring harness and connectors through any clips or guides. Place pump on clean work surface for inspection or disposal.
6. 6

   Clean mounting surfaces
   Use wire brush to clean mounting bracket surfaces on inner fender well, removing any rust, debris, or old gasket material. Wipe clean with shop towel. Inspect bracket for damage or cracks.
7. 7

   Install new pump to bracket
   Position new secondary air injection pump onto mounting bracket, aligning all three mounting bolt holes. Start all three mounting bolts by hand to ensure proper alignment before tightening.
8. 8

   Torque mounting bolts
   Tighten the three pump mounting bolts in a crisscross pattern to ensure even seating. Torque each bolt to specification using torque wrench.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
9. 9

   Install check valve assembly
   Install new outlet gasket onto pump outlet port. Position check valve assembly with arrow pointing away from pump toward exhaust manifold. Install flange bolts finger-tight, then torque to specification in crisscross pattern.
   ⚠Verify check valve orientation is correct before tightening. Incorrect installation will prevent air injection system from functioning and may set diagnostic codes.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
10. 10

    Connect air inlet hose
    Install new inlet gasket if equipped, or inspect existing hose end for damage. Slide air inlet hose onto pump inlet fitting, ensuring hose seats fully onto barbed fitting. Position hose clamp over hose and tighten securely.
11. 11

    Reconnect electrical connector
    Route wiring harness through original clips and guides. Push electrical connector onto pump terminal until it clicks into place. Tug gently to verify secure connection.

Reassembly

1. Reinstall engine cover by pressing down firmly on mounting clips until they click into place
2. Reconnect negative battery terminal and tighten securely
3. Double-check all connections, hoses, and fasteners for proper installation

Verification

• Start engine and allow to idle. Listen for abnormal noises from air pump location
• Verify no air leaks are present at pump inlet or outlet connections
• Using scan tool, monitor secondary air injection system operation during cold start - pump should activate for 60-120 seconds
• Check for diagnostic trouble codes related to secondary air injection system - clear any codes and verify they do not return
• Perform test drive and verify no check engine light illumination or driveability issues

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