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Secondary Air Pump Replacement
 
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Pelican Technical Article:

Secondary Air Pump Replacement

Steve Vernon

Time:

2 hours2 hrs

Tab:

$240 to $800

Talent:

**

Tools:

E30, E25 Torx

Applicable Models:

Mercedes-Benz W204 (2008-15)

Parts Required:

New air pump

Hot Tip:

Use care working on old rubber hoses

Performance Gain:

Pass a smog test

Complementary Modification:

Air pump check valves

If your car is not passing a smog test one of the things that could be wrong is the secondary air pump. This article will show you how to replace the air pump on a Mercedes-Benz W204 C350.

The pump is connected to the motor by a mount that needs to be transferred to the new pump so be aware and do not throw the old pump out with the mount attached. You do not get the mount with the new pump.

The secondary air pump is located at the front of the engine under the engine cover (red arrow).
Figure 1

The secondary air pump is located at the front of the engine under the engine cover (red arrow).

Remove the front cover by grabbing it by the front and pulling it up and off (red arrow).
Figure 2

Remove the front cover by grabbing it by the front and pulling it up and off (red arrow).

While you could technically replace the pump with the air ducts and rear engine cover on, give yourself some more room to work and remove the ducts by compressing them away from the air filter inlet (red arrow).
Figure 3

While you could technically replace the pump with the air ducts and rear engine cover on, give yourself some more room to work and remove the ducts by compressing them away from the air filter inlet (red arrow).

With the ducts off the engine cover / air filter inlet, slip them off the air duct on the front (red arrow).
Figure 4

With the ducts off the engine cover / air filter inlet, slip them off the air duct on the front (red arrow).

The pump (yellow arrow) is connected to the air box by a hose (red arrow).
Figure 5

The pump (yellow arrow) is connected to the air box by a hose (red arrow). Lift the rear cover off and the hose will separate from it.

With the engine cover off remove the hose from the front of the pump (red arrow).
Figure 6

With the engine cover off remove the hose from the front of the pump (red arrow).

Disconnect the hose from the left check valve by pulling it off with your hand (red arrow).
Figure 7

Disconnect the hose from the left check valve by pulling it off with your hand (red arrow).

Remove the electrical connection from the rear of the pump by squeezing in the tabs and pulling the connection off (red arrow).
Figure 8

Remove the electrical connection from the rear of the pump by squeezing in the tabs and pulling the connection off (red arrow).

Use a T25 Torx and remove the four bolts (red arrows), making sure to pay attention to the length, as the bolts are different.
Figure 9

Use a T25 Torx and remove the four bolts (red arrows), making sure to pay attention to the length, as the bolts are different.

With the pump free from the engine you can lift it up off the right side check valve hose (red arrow) and out of the engine.
Figure 10

With the pump free from the engine you can lift it up off the right side check valve hose (red arrow) and out of the engine.

You will have to remove the air pump from the mount that connects it to the engine block; use a T30 Torx and remove the old pump and install the new pump to the mount (red arrows).
Figure 11

You will have to remove the air pump from the mount that connects it to the engine block; use a T30 Torx and remove the old pump and install the new pump to the mount (red arrows). Installation is the reverse of removal.

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Comments and Suggestions:
RP Comments: a few observations on this repair for my 08 C300. The only tool needed was a ratchet and a T30 Torx. No E Torx needed. There were 5 bolts to remove and the ones on the lower part of the bracket are a bit difficult to access due to lack of room and the belt being in the way. So be prepared to drop the bolts a few times when reinstalling.
August 26, 2016
  Followup from the Pelican Staff: Thanks for sharing your installation process and experience. These type of comments add so much to the Pelican tech community.
- Nick at Pelican Parts
 

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