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EGR Change Over Valve Replacement
 
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Pelican Technical Article:

EGR Change Over Valve Replacement

Steve Vernon

Time:

1 hour1 hr

Tab:

$40 to $100

Talent:

*

Tools:

Hands

Applicable Models:

Mercedes-Benz C350 (2008-14)
Mercedes-Benz GLK350 (2010-14)

Parts Required:

EGR change over valve(s)

Hot Tip:

Order some vacuum hose before you start

Performance Gain:

Pass a SMOG test

Complementary Modification:

Change the oil filter

If you are having trouble passing a SMOG test and getting an error code that the EGR change over valves are faulty you can replace them yourself, though you are going to have a fair amount of work ahead of you. The valves are located at the front bottom of the intake manifold and cannot be accessed without removing the intake from the engine. Please see our article on intake manifold removal for step-by-step instructions.

If you are replacing the valves it is a good idea to order some replacement vacuum hose along with the valves. The rubber vacuum hose that attaches the valves to the hard lines gets very brittle. You do not want to hang up the job over a couple of inches of vacuum line.

The valves are the same and interchangeable.

The valves are located at the front bottom of the intake manifold (red arrows) and cannot be accessed without removing the intake from the engine.
Figure 1

The valves are located at the front bottom of the intake manifold (red arrows) and cannot be accessed without removing the intake from the engine. Please see our article on intake manifold removal for step-by-step instructions.

The valves are mounted onto the front of the manifold by four sturdy plastic clips (red arrows).
Figure 2

The valves are mounted onto the front of the manifold by four sturdy plastic clips (red arrows). To remove the valve you will need to squeeze in and hold the clips together while sliding the valve off the mount.

With the valve off the mount push in the metal clip on the electrical connection and separate it from the valve (red arrow).
Figure 3

With the valve off the mount push in the metal clip on the electrical connection and separate it from the valve (red arrow).

Pay close attention to the routing of the lines attached to the valve as it is a tight fit to get everything back together.
Figure 4

Pay close attention to the routing of the lines attached to the valve as it is a tight fit to get everything back together. Carefully remove the lines from the valve (red arrows). It is a good idea to replace these lines even if you get them off successfully. A crack or leak in the old line later will mean removing the intake manifold again.

Replacement of the other valve is the same procedure again using care with the rubber lines.
Figure 5

Replacement of the other valve is the same procedure again using care with the rubber lines. Installation is the reverse of removal.


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Comments and Suggestions:
Omar S. Comments: Thank you for following up.

I -was- working on a 2008 C300 Sport 3.0L Engine: 272.947, replacing the intake manifold. Thankfully, I completed that yesterday. The C300, by the way, has the same part number you posted for those two control valves see image showing the C300 intake manifold having the same part # here: http://imgur.com/FnAu8h6. However, I did some research after posting my last comments, and I was able to establish that one of those parts is actually the intake manifold switch-over valve, which in turn controls the intake manifold switch-over diaphragm unit capsule... whereas the other one is the intake manifold tumble flap switch-over valve which controls the two aneroid capsules which in turn control the intake manifold tumble flaps. You'll see a similar set up in the image I linked below, with the only variable being that the 272 engine has two tumble flap switch-over capsules, plus one switch-over diaphragm capsule, whereas the 273 engine shown in the image has one of each. http://imgur.com/WVRjF51

So for accuracy's sake, this leaves the EGR Changeover valve as being as I described above. The part number there would be 002 540 70 97 which is this part that you carry: http://www.pelicanparts.com/cgi-bin/ksearch/pel_search_2014.cgi?SUPERCAT_FLAG=Y&make=MBZ&Context_make=MBZ&please_wait=N&LastVisited_input=&Previous_Section=&forumid=&threadid=&command=DWsearch&description=0025407097&I1.x=0&I1.y=0
March 23, 2016
  Followup from the Pelican Staff: Correct, the intake manifold solenoid is there as well.

Thanks for the additional info. We appreciate it. I will have the article updated.
- Nick at Pelican Parts
 
Omar S. Comments: OK... So if those two parts that are the bottom front of the intake manifold are indeed the changeover valves, does that mean that there are 3 changeover valves on this model MBZ? Because searching MBZ's parts catalog for "changeover" it comes up with one changeover valve which is shown to be located at the front passenger side of the engine bay, just in front of the alternator with several vacuum lines going into/coming out of it. See this blow up chart: http://imgur.com/cKS53Js specificalluy, Part labeled as "200" with an OEM part # that is 0025407097 and is described as "Changeover Valve"?

In fact, here it is in your parts catalog: http://www.pelicanparts.com/cgi-bin/ksearch/PEL_search_2014.cgi?command=show_part_page&please_wait=N&SUPERCAT_FLAG=Y&make=MBZ&model=4194§ion=fulemi&page=1&bookmark=4&part_number=002-540-70-97-MBZ

That said, can you also please provide a part number for the valves you demonstrated replacing in this DIY.

Thanks in advance for any information...
March 20, 2016
  Followup from the Pelican Staff: The solenoids shown in this article are for the EGR change over valve. I confirmed it via part number. 002 540 18 97

What vehicle are you working on?




Give our parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 

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