exhaust

Secondary Air Injection Pump

for 2014 Ram 2500 6.7L I6 Cummins Diesel · 4WD

Difficulty

Moderate

Time

2.4 h

Tools

Steps

This procedure covers the removal and replacement of the secondary air injection pump on a 2014 Ram 2500 with the 6.7L Cummins Diesel engine.

Warnings

⚠️Allow engine and exhaust system to cool completely before beginning work. Exhaust components can remain extremely hot for over an hour after engine shutdown.

⚠Disconnect negative battery cable before working on electrical components to prevent short circuits.

⚠Support vehicle on jack stands only, never work under a vehicle supported only by a jack.

ℹ️The secondary air injection system operates during cold starts to reduce emissions. A failed pump may trigger check engine light with codes related to air injection flow.

Tools required

Socket set (10mm-19mm)Essential

Ratchet and extensionsEssential

Torque wrenchEssential

Anti-seize compoundEssential

Penetrating oil

Wire brush

Electrical connector release tools

Jack and jack standsEssential

Wheel chocksEssential

Parts

Secondary air injection pump × 1 — Use OEM specification
Air injection pump mounting gasket × 1 — Use OEM specification
Air injection inlet hose (if damaged) × 1 — Inspect and replace as needed

Preparation

Park vehicle on level surface and apply parking brake
Place wheel chocks behind rear wheels
Allow engine and exhaust system to cool completely (minimum 2 hours)
Disconnect negative battery cable
Raise front of vehicle and secure on jack stands at frame contact points
Remove passenger side front wheel for improved access
Spray all exhaust connections and mounting bolts with penetrating oil and allow to soak

Procedure

1
Access secondary air injection pump
From underneath the vehicle on the passenger side, locate the secondary air injection pump mounted near the frame rail forward of the front axle. Remove any splash shields or heat shields that obstruct access to the pump assembly.
Torque spec
Heat Shield Bolts10 Nm (7 lb-ft)
2
Disconnect electrical connector
Locate the electrical connector on the secondary air injection pump motor. Press the release tab and carefully disconnect the wiring harness. Inspect connector terminals for corrosion or damage.
3
Remove inlet air hose
Loosen the hose clamp securing the air inlet hose to the pump intake. Carefully remove the hose and inspect for cracks, deterioration, or blockages. Set aside for reinstallation or replacement.
4
Disconnect outlet air line to exhaust
Locate the metal air delivery line running from the pump outlet to the exhaust manifold. Disconnect the line at the pump outlet by removing the flange connection or threaded fitting. Some penetrating oil may be needed on corroded connections.
Torque spec
Exhaust Flange Bolts45 Nm (33 lb-ft)
5
Remove pump mounting bolts
Remove the mounting bolts securing the secondary air injection pump to the frame bracket. Support the pump weight as you remove the final bolt. Note the orientation and position of any spacers or brackets for reassembly.
Torque spec
Mounting Bolts37 Nm (27 lb-ft)
6
Remove pump assembly
Carefully lower and remove the secondary air injection pump assembly from the vehicle. Maneuver it through the frame and suspension components. Inspect the mounting bracket for damage or corrosion.
7
Inspect exhaust connection points
With the pump removed, inspect the exhaust manifold connection point where the air injection line attaches. Clean any carbon buildup with a wire brush. Check the check valve at the exhaust connection for proper operation and replace if defective.
8
Prepare new pump for installation
Unpack the new secondary air injection pump and verify it matches the original unit. Install any mounting brackets or fittings that transfer from the old pump. Apply a thin layer of anti-seize to all threaded exhaust connections and mounting bolt threads.
9
Install new pump assembly
Position the new pump into the mounting location, carefully routing it through frame and suspension components. Align the pump with the mounting bracket holes. Install mounting bolts finger-tight initially to allow for alignment adjustments.
Torque spec
Mounting Bolts37 Nm (27 lb-ft)
10
Connect outlet air line
Connect the air delivery line from the pump outlet to the exhaust manifold connection. Ensure the connection is properly seated and aligned. Install flange bolts and torque to specification. Apply anti-seize to exhaust connection threads as specified.
Torque spec
Exhaust Flange Bolts45 Nm (33 lb-ft)
11
Connect inlet air hose
Install the air inlet hose (new or original if in good condition) onto the pump intake. Position the hose clamp and tighten securely, ensuring the hose is fully seated on the barbed fitting.
12
Connect electrical connector
Plug the wiring harness connector into the new pump motor. Ensure the connector locks fully with an audible click. Gently tug on the connection to verify it is secure.
13
Reinstall heat shields and underbody panels
Reinstall any heat shields or splash shields removed during disassembly. Torque all fasteners to specification and verify all components are secure.
Torque spec
Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

Reinstall passenger side front wheel and torque lug nuts to specification
Lower vehicle from jack stands
Reconnect negative battery cable
Clear any diagnostic trouble codes using a scan tool

Verification

Start the engine from cold and listen for secondary air pump operation during the first 30-90 seconds of running (pump should run briefly during cold start)
Verify no unusual noises from the pump area during operation
Check for air leaks at all connections using soapy water solution while pump is operating
Confirm no check engine light or air injection system codes are present
Take vehicle for a test drive and perform a cold start cycle the following day to confirm proper operation
Monitor for any exhaust leaks at the air injection connection point