Secondary Air Injection Pump

This procedure covers the removal and replacement of the secondary air injection pump on a 2017 Maserati Levante with the 3.0L V6 Twin Turbo engine, including disconnection of electrical connectors, hoses, and mounting hardware.

Warnings

Tools required

Parts

• Secondary air injection pump × 1 — Use OEM specification
• Air pump inlet filter × 1 — Replace if contaminated
• Mounting rubber isolators × 2 — Inspect and replace if damaged
• Hose clamps × 2 — Replace if corroded

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 5 minutes for system capacitors to discharge
4. Remove engine cover by pulling upward on front corners to release retaining clips
5. Document routing of all hoses and electrical connections with photos for reference during reassembly

Procedure

1. 1

   Access secondary air pump location
   The secondary air injection pump is located on the passenger side of the engine bay, forward of the wheel well. Remove the passenger side wheel well liner by removing the plastic fasteners along the front edge. This provides access to the pump from below.
2. 2

   Disconnect electrical connector
   Locate the electrical connector on the secondary air pump motor. Press the locking tab and pull the connector straight off the pump. Inspect the connector terminals for corrosion or damage.
3. 3

   Remove inlet air hose and filter
   Using hose clamp pliers, compress the clamp securing the inlet air hose to the pump. Slide the clamp back along the hose and disconnect the hose from the pump inlet. Remove the air filter element from the inlet if equipped and inspect for contamination.
4. 4

   Disconnect outlet hose to check valve
   Locate the outlet hose that connects the pump to the secondary air check valve on the exhaust manifold. Compress the hose clamp and slide it back. Disconnect the hose from the pump outlet. Cap or plug the check valve side to prevent debris entry.
   ⚠Inspect the check valve for proper operation. It should allow air flow in one direction only. A failed check valve can cause exhaust gases to damage the new pump.
5. 5

   Remove pump mounting bolts
   Remove the mounting bolts securing the secondary air pump to its bracket. The pump is typically secured with two or three bolts through rubber isolators. Support the pump while removing the final bolt to prevent it from falling.
6. 6

   Remove pump from vehicle
   Carefully maneuver the secondary air pump out of the engine bay through the wheel well opening. Note the orientation of the pump and any support brackets for proper installation of the replacement unit.
7. 7

   Inspect mounting bracket and hardware
   Examine the mounting bracket for cracks or damage. Check the rubber isolators for deterioration, cracking, or excessive compression. Clean the mounting surfaces with a wire brush to remove corrosion. Replace any damaged isolators or hardware.
8. 8

   Install new secondary air pump
   Position the new pump in the mounting bracket, ensuring proper orientation matches the original installation. Install new rubber isolators if the originals show wear. Thread the mounting bolts by hand to prevent cross-threading.
9. 9

   Torque mounting bolts
   Using a torque wrench, tighten the pump mounting bolts to specification in a cross pattern to ensure even clamping force on the rubber isolators. Do not overtighten as this can damage the isolators and transfer vibration.
10. 10

    Reconnect outlet hose
    Connect the outlet hose to the pump outlet port, ensuring it is fully seated. Slide the hose clamp into position approximately 10mm from the end of the hose and secure it firmly. Verify the hose has no kinks or sharp bends that could restrict airflow.
11. 11

    Install inlet filter and hose
    Install a new or cleaned air filter element on the pump inlet. Connect the inlet air hose, ensuring full engagement with the pump inlet port. Position and secure the hose clamp.
12. 12

    Reconnect electrical connector
    Plug the electrical connector onto the pump motor until the locking tab clicks into place. Gently tug on the connector to verify it is fully secured. Ensure the wiring harness has adequate slack and is routed away from hot or moving components.
13. 13

    Reinstall wheel well liner and engine cover
    Reinstall the passenger side wheel well liner, securing all plastic fasteners. Ensure the liner does not interfere with any hoses or wiring. Replace the engine cover by aligning the retaining clips and pressing down firmly until seated.

Reassembly

1. Reconnect the negative battery terminal and ensure secure connection
2. Verify all hose clamps are properly secured and hoses are not kinked
3. Double-check that all fasteners have been reinstalled and torqued to specification
4. Ensure electrical connector is fully engaged with locking tab secured

Verification

• Start the engine and listen for unusual noises from the secondary air pump area during cold start
• The secondary air pump should operate for approximately 60-120 seconds during cold start. Listen for smooth operation without grinding or squealing
• Using a diagnostic scan tool, verify no fault codes are present for the secondary air injection system (P0410, P0411, P0412, P0418, P2430, P2431, P2433, P2440, P2443)
• Check for air leaks at all hose connections by listening for hissing sounds during pump operation
• Perform a drive cycle: drive the vehicle for at least 15 minutes including highway speeds, then shut off and allow to cool for 8 hours. Start cold and verify pump operation
• Recheck all connections after first drive cycle to ensure nothing has loosened due to vibration

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

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