Secondary Air Injection Pump

This procedure covers the removal and replacement of the secondary air injection pump on 2019-2024 Toyota RAV4 vehicles equipped with the 2.5L I4 gasoline engine and front-wheel drive.

Warnings

Tools required

Parts

• Secondary air injection pump assembly × 1 — Use OEM specification
• Air pump inlet filter (if damaged) × 1 — Use OEM specification
• Mounting gasket (if applicable) × 1 — Use OEM specification

Preparation

1. Ensure engine is completely cold (minimum 2 hours after last operation)
2. Park vehicle on level surface and engage parking brake
3. Open hood and secure with prop rod
4. Disconnect negative battery terminal and wait 90 seconds for system discharge
5. Locate the secondary air injection pump mounted on the driver's side of the engine bay near the front fender

Procedure

1. 1

   Remove engine cover and access panels
   Remove the plastic engine cover by lifting upward at the pull points. If equipped, remove any additional covers or shields that obstruct access to the secondary air injection pump area on the driver's side front of the engine bay.
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. Inspect the connector for corrosion or damage.
3. 3

   Remove air inlet hose
   Loosen the hose clamp securing the air inlet hose to the secondary air injection pump inlet. Slide the clamp back and disconnect the hose from the pump. Inspect the inlet filter screen on the pump; replace if clogged or damaged.
4. 4

   Disconnect outlet hose and pipe
   Locate the air outlet pipe connected to the pump discharge port. Loosen the clamp or fastener securing this connection. Carefully separate the outlet pipe from the pump, taking care not to damage the rubber coupling or check valve assembly.
5. 5

   Remove pump mounting bolts
   Identify the mounting bolts securing the secondary air injection pump to its bracket (typically 2-3 bolts). Using the appropriate socket, remove these mounting bolts while supporting the pump with your other hand. Note the bolt locations and any spacers or washers for reinstallation.
6. 6

   Remove pump assembly
   Carefully maneuver the secondary air injection pump out of the engine bay. There may be limited clearance; rotate and angle the pump as needed to clear surrounding components. Inspect the mounting bracket and hardware for damage or excessive corrosion.
7. 7

   Prepare new pump for installation
   Unpack the new secondary air injection pump and verify it matches the original unit. Transfer any necessary brackets or hardware from the old pump if they are not included with the replacement. Inspect all hose connections and ensure the inlet filter is clean and properly installed.
8. 8

   Install new pump assembly
   Position the new secondary air injection pump into the mounting location, routing it carefully past surrounding components. Align the mounting holes with the bracket. Install the mounting bolts hand-tight initially, ensuring any spacers or washers are in their correct positions.
9. 9

   Reconnect outlet pipe
   Connect the air outlet pipe to the pump discharge port. Ensure the rubber coupling or check valve is properly seated and oriented correctly (check valve must allow flow only in the correct direction). Tighten the clamp or fastener securely.
10. 10

    Reconnect inlet hose
    Attach the air inlet hose to the pump inlet fitting, ensuring it is fully seated. Position the hose clamp over the connection area and tighten securely. Verify the hose routing does not create any kinks or contact with hot exhaust components.
11. 11

    Reconnect electrical connector
    Plug the electrical connector onto the secondary air injection pump until you hear or feel a positive click, indicating the locking tab has engaged. Gently tug on the connector to verify it is fully locked in place.
12. 12

    Reinstall covers and reconnect battery
    Reinstall the engine cover and any removed access panels or shields, ensuring all fasteners are properly tightened. Reconnect the negative battery terminal. Clear any stored diagnostic trouble codes if you have access to a scan tool.

Reassembly

1. Double-check all electrical connections are fully seated and locked
2. Verify all hose clamps are tight and hoses are properly routed
3. Ensure no tools or parts have been left in the engine bay
4. Confirm engine cover and shields are securely fastened

Verification

• Start the engine from cold and listen for abnormal noises from the secondary air pump area during the first 60-90 seconds of operation
• Verify the check engine light does not illuminate with secondary air system codes (P0410, P0418, P0419, P0441, P0442)
• Monitor for any air leaks at hose connections during pump operation
• Perform a test drive and verify no warning lights appear on the instrument cluster
• If available, use a scan tool to verify secondary air injection system data shows proper operation during cold start conditions

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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