I have had my secondary Air pump out of my car for a few months, the hole is pluged and everything. The pump is all clogged up and doesn't turn very well. It still draws a few amps though. I was wondering if anyone has ever tried to rebuild one of them. I started to take the pump apart, but haven't gotten very far, I'm having a hard time getting the rotor off, but I'll get it off eventually. If someone has taken one apart or has a diagram of one, let me know, or if someone out there has done something else to fix that stupid pump.

I have wondered the same thing. I am gonna attempt this soon also.

I have an extra one. See my check valve thread :mad

I tried. These are difficult to dismantle. The fan is pressed on the shaft, and I could see no way to remove it, therefore the case could not be separated. I finally cut everything apart out of curiosity. The unit is not designed to me dismatled, and once apart , the motor itself is pressed together. Therefore it could not be repaired.
What I will say is the motor is very well sealed and the comment that it gets damaged from moisture is wrong. In my case, the motor had an internal short and was toast. I think the motor design is poor and this is what causes the failure.

I think the most common failure of the secondary air pump is corrosion of the internals. While the casing of the pump is well sealed, a bad valve allows exhaust gases to back flow into the pump. That moisture will collect in the pump and cause failure.

I think the most common failure of the secondary air pump is corrosion of the internals. While the casing of the pump is well sealed, a bad valve allows exhaust gases to back flow into the pump. That moisture will collect in the pump and cause failure.exact-a-mundo

I thought my secondary air pump was bad because it does not come on and run. I took it off and put 12 volts to it and it ran ok. So I then checked to see if I had power to the pump. What I did was just use a test light to see if the wire/plug had electric going thru it. All I have is one of those screw driver type testers with a ground clip and one prong that you touch to what ever you are trouble shooting if it lights you have power.Mine did not light and I know it works ok.I already replaced my 50 amp fuse.Any suggestions ?

I think the most common failure of the secondary air pump is corrosion of the internals. While the casing of the pump is well sealed, a bad valve allows exhaust gases to back flow into the pump. That moisture will collect in the pump and cause failure.

If the valve was bad, and if exhaust gasses were routed back thru the pump, these gasses and whatever they carried would vent out thru the pump intake. There is virtually no way for these gasses to enter the motor. The motor shaft has a seal where it passes thru the plastic housing. If you would take a look at one, you will also agree that nothing is getting past the seal.
The part of the pump (rotating fan) that would be exposed to the gasses, is separted from the motor, and even if high pressure was present, it would vent out of the intake before it would compromise the shaft seal.
Other than an electrical motor failure, there is zero that can go wrong with these pumps. Unfortunatley, the motor design is poor.

Its a good idea but prob easier to just replace it

Hey, thanks for all the advice on the pump, I'll see what I can do with it.

I've been getting P1421 and P1423 faults for a while, which point to a an air pump failue. I removed the unit, and on the bench, applied 12 VDC to it-no response. I expected it to turn... I removed the top air filter, and with that off , you can see down to the impeller. There is a hole on the visible end of the shaft, and if you can wedge something in there, you should be able to turn that shaft. Mine wouldn't turn; it has seized. Several applications of WD40 later, i could get it to turn, but now smoothly.
It looks like I've nothing to loose (but some time) so I will dissassemble the pump and see what's going on. I'll let you know what I find-anyone who might have been down this road already, I'd appreciate your sharing your experiences.

my car is having problems with my secondary air pump also so id liek to no also if i can rebuild it