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Secondary Air System Component Replacement
 
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Pelican Technical Article:

Secondary Air System Component Replacement

Nick Czerula

Time:

2 hours2 hrs

Tab:

$200

Talent:

*****

Tools:

Set of sockets, E12, 10mm, flathead, Phillips screwdriver

Applicable Models:

Mercedes-Benz W211 (2003-09)

Parts Required:

Secondary air valve and gasket, hose clamps, secondary air solenoid

Hot Tip:

Replace any cracked or dry rotted hoses

Performance Gain:

Repair inoperative secondary air

Complementary Modification:

Replace companion component

Secondary air injection is a vehicle emission control wherein fresh air is injected into the exhaust stream to allow for a more efficient catalytic converter. The air injection point is called the upstream injection point. When the engine is cold, air is injected upstream of the catalytic converter to clean up the extra-rich exhaust and raises the temperature of the exhaust to bring the catalytic converter to operating temperature quickly. Once the engine is warm, air injection is halted. This function usually only runs for a short time, when first starting the engine.

The secondary air system is prone to faults that illuminate the check engine light. If you have fault codes for your secondary air, check the operation of the pump. You can test the function of the secondary air components using a Mercedes-Benz scan tool. If you do not have access to one, you can check secondary air pump function when starting the engine. When a cold engine is started, the secondary air pump will run for a calculated amount of time. You can also manually test each item. See our tech article on secondary air system testing.

Remember that your car may have been serviced before and had parts replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you're working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Never work on your vehicle if you feel the task is beyond your ability.

The secondary air valves are located at the left and right corners of the engine (green arrows).
Figure 1

The secondary air valves are located at the left and right corners of the engine (green arrows). The secondary air solenoid is located at the right front of the engine (red arrow).

Working at the engine cover (red arrow), pull off the two front air duct hoses (green arrows).
Figure 2

Working at the engine cover (red arrow), pull off the two front air duct hoses (green arrows).

To detach the ducts, pull them straight off the engine cover / air filter housing.
Figure 3

To detach the ducts, pull them straight off the engine cover / air filter housing. Then pull the front of the duct out of the radiator support and remove it from the engine. Repeat this step for each duct.

Lift up and remove the front engine cover.
Figure 4

Lift up and remove the front engine cover.

Then, pull the engine cover / air filter housing straight up to remove it.
Figure 5

Then, pull the engine cover / air filter housing straight up to remove it. The cover is held on by four metal clips that grab onto rubber mounts. The front two are shown (red arrows). The rear of the cover has two as well. Once detached, remove the engine cover / air filter housing from the engine.

Secondary air pump check valve replacing: Start by removing the vacuum hose (red arrow) from the secondary air check valve.
Figure 6

Secondary air pump check valve replacing: Start by removing the vacuum hose (red arrow) from the secondary air check valve. Depending on the part you have, you may be replacing the upper valve, or the valve with the pedestal. I will show how to get the valve off first, and then the pedestal. If you have a pedestal and a valve as a unit, skip the steps involved with removing the valve and go right to removing the pedestal.

Secondary air pump check valve replacing: Next you will have to disconnect the air pipe.
Figure 7

Secondary air pump check valve replacing: Next you will have to disconnect the air pipe. Start by removing the pipe from the secondary air pump.

Secondary air pump check valve replacing: Then remove the pipe from the valve you are replacing.
Figure 8

Secondary air pump check valve replacing: Then remove the pipe from the valve you are replacing.

Secondary air pump check valve replacing: Working at the valve, remove the two Phillips head screws (red arrows).
Figure 9

Secondary air pump check valve replacing: Working at the valve, remove the two Phillips head screws (red arrows).

Secondary air pump check valve replacing: Remove the valve from the pedestal.
Figure 10

Secondary air pump check valve replacing: Remove the valve from the pedestal. If you're just replacing the valve, you can reverse the steps now to install the replacement.

Secondary air pump check valve replacing: To remove the pedestal (green arrow), remove the E12 fastener (red arrow).
Figure 11

Secondary air pump check valve replacing: To remove the pedestal (green arrow), remove the E12 fastener (red arrow).

Secondary air pump check valve replacing: Then remove the pedestal from the engine.
Figure 12

Secondary air pump check valve replacing: Then remove the pedestal from the engine. Depending on the condition of your engine, the pedestal may be frozen. If it is, spray penetrating oil around the base and allow it soak for a few hours. Then try to free it by slightly rotating the pedestal until it is free. Then remove the pedestal by pulling straight up. Reverse the removal steps to install the new part.

Secondary air solenoid replacing: To replace the secondary air solenoid, start by removing the vacuum hoses (red arrows).
Figure 13

Secondary air solenoid replacing: To replace the secondary air solenoid, start by removing the vacuum hoses (red arrows). I suggest marking them if you are concerned with mixing them up. However, the hoses are different sizes, so it is hard to do. The vacuum source from the intake manifold is the smaller hose. The larger hose runs to the secondary air check valves.

Secondary air solenoid replacing: Disconnect the solenoid electrical connector by pressing the release tab and pulling the connector (red arrow) straight off.
Figure 14

Secondary air solenoid replacing: Disconnect the solenoid electrical connector by pressing the release tab and pulling the connector (red arrow) straight off.

Secondary air solenoid replacing: Move the plastic retaining tab away from the solenoid to the right side of the engine and hold it while lifting the solenoid in the direction of the red arrow.
Figure 15

Secondary air solenoid replacing: Move the plastic retaining tab away from the solenoid to the right side of the engine and hold it while lifting the solenoid in the direction of the red arrow. Reverse these steps to install the new solenoid.

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