exhaust

Secondary Air Injection Pump

for 2021 Toyota RAV4 2.5L I4 · AWD

Difficulty

Moderate

Time

1.6 h

Tools

Steps

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

⚠️Perform this work only when the engine is completely cold. Exhaust components and the air injection system reach extremely high temperatures during operation.

⚠Always disconnect the negative battery terminal before working on electrical components to prevent short circuits and airbag deployment.

⚠The secondary air injection pump operates during cold starts. Ensure the vehicle will not be started during this procedure.

Tools required

10mm socket and ratchetEssential

12mm socket and ratchetEssential

14mm socket and ratchetEssential

Extension setEssential

Torque wrenchEssential

Flat blade screwdriver

Anti-seize compoundEssential

Trim removal tools

Wire brush

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

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

Procedure

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.
Torque spec
Cover Screws11 Nm (8 lb-ft)
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
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
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
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.
Torque spec
Mounting Bolts27 Nm (20 lb-ft)
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
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
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.
Torque spec
Mounting Bolts27 Nm (20 lb-ft)
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
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
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
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.
Torque spec
Cover Screws11 Nm (8 lb-ft)

Reassembly

Double-check all electrical connections are fully seated and locked
Verify all hose clamps are tight and hoses are properly routed
Ensure no tools or parts have been left in the engine bay
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