This procedure covers the removal and replacement of the secondary air injection pump on the 2018-2024 Toyota Camry 2.5L I4 engine, which helps reduce emissions during cold starts.

Warnings

Tools required

Parts

• Secondary air injection pump assembly × 1 — Use OEM specification
• Pump mounting gasket (if equipped) × 1 — Use OEM specification
• Air injection hose clamps × 2 — Replace if damaged

Preparation

1. Ensure the engine has been off for at least 2 hours and is completely cold
2. Park the vehicle on a level surface and engage the parking brake
3. Disconnect the negative battery terminal and wait 90 seconds
4. Remove the engine cover by pulling upward on the clips
5. Locate the secondary air injection pump on the driver's side of the engine compartment, near the front

Procedure

1. 1

   Disconnect electrical connector
   Locate the electrical connector on the secondary air injection pump. Press the locking tab and disconnect the connector. Move the wiring harness aside to provide clearance.
2. 2

   Remove air inlet hose
   Locate the air inlet hose connected to the intake side of the pump. Use a flathead screwdriver or pliers to loosen the hose clamp. Slide the clamp back and remove the hose from the pump inlet. Inspect the hose for cracks or deterioration.
3. 3

   Disconnect air injection delivery hose
   Locate the delivery hose that connects the pump to the exhaust manifold. Loosen the hose clamp using a flathead screwdriver or appropriate tool. Carefully disconnect the hose from the pump outlet. Note the routing for reinstallation.
4. 4

   Remove pump mounting bolts
   Using a 12mm socket and ratchet, remove the mounting bolts securing the secondary air injection pump to its bracket. There are typically 2-3 bolts. Support the pump with one hand while removing the final bolt to prevent it from falling.
   Torque spec

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

   Remove pump assembly
   Carefully lift the secondary air injection pump assembly from the engine compartment. Maneuver it around any nearby hoses or wiring. Inspect the mounting bracket and gasket (if equipped) for damage or deterioration.
6. 6

   Prepare new pump for installation
   Remove the new secondary air injection pump from its packaging. Verify that all inlet and outlet ports are free of debris or protective caps. If a gasket is used between the pump and mounting bracket, install it now. Apply a thin coat of anti-seize to the threads of the mounting bolts.
7. 7

   Install new pump assembly
   Position the new secondary air injection pump onto the mounting bracket, aligning the bolt holes. Start all mounting bolts by hand to ensure proper thread engagement. Using a torque wrench and 12mm socket, tighten the mounting bolts to specification in a cross-pattern.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
8. 8

   Reconnect air injection delivery hose
   Connect the delivery hose to the outlet port of the new pump. Ensure the hose is fully seated on the port. Position the hose clamp over the connection point and tighten securely. Verify the hose routing matches the original configuration.
9. 9

   Reconnect air inlet hose
   Connect the air inlet hose to the intake side of the pump. Ensure the hose is fully seated. Position the hose clamp and tighten securely. Check that the hose is not kinked or stretched.
10. 10

    Reconnect electrical connector
    Connect the electrical connector to the secondary air injection pump. Ensure the connector locks into place with an audible click. Verify the wiring harness is properly routed and secured away from hot or moving components.

Reassembly

1. Reinstall the engine cover by pressing down on the mounting clips until they snap into place
2. Reconnect the negative battery terminal and tighten securely
3. Do not start the engine until all connections have been verified

Verification

• Start the engine and allow it to idle. Listen for any unusual noises from the secondary air injection pump area during the first 60-90 seconds of operation (when the system is active during cold start)
• Check for air leaks at the hose connections by feeling for escaping air or listening for hissing sounds during cold start operation
• Verify no warning lights illuminate on the instrument cluster, particularly the check engine light or malfunction indicator lamp
• Use an OBD-II scanner to verify no diagnostic trouble codes (DTCs) are present related to the secondary air injection system (P0410-P0419 range)
• Perform a cold start test: turn off the engine, wait 30 minutes, then restart and confirm the pump operates for approximately 60-90 seconds

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