Removing and installing/replacing electrical wastegate valve controller

Special tools required:

2 469 240

WARNING: High-voltage system - danger to life
Compliance with the following points is mandatory before beginning work:

Observe 61 00... SAFETY INSTRUCTIONS ON HANDLING HYBRID CARS .

CAUTION: Read and comply with notes on PROTECTION AGAINST ELECTROSTATIC DISCHARGE (ESD PROTECTION) !

Necessary preliminary work:

Remove CLEANING AIR PIPE .

Removal:

Have special tool 2 469 240 ready.

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Unlock and disconnect plugs (1).

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Remove color coding (1) with commercially available tool.

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Sand commercially available open-end spanner (1) with the dimension (A) indicated on the caliper gauge (2).

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CAUTION: The lock nut (4) must be loosened with two open-end spanners. If only one open-end spanner is used, there is a risk of the electrical controller drive being damaged.

Counter-hold adjusting nut (3) with the sanded commercially available open-ended spanner (2).

Release lock nut (4) with a standard open-end spanner (1).

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Guide out lock nut (1) and remove.

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Carefully guide out lever (1) of the wastegate valve in direction of arrow from the control rod of the electrical wastegate valve controller and set aside.

Avoid any lateral force on the control rod of the electrical wastegate valve controller.

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Loosen screws (1) with the special tool 2 469 240 .

Guide out electrical wastegate valve controller (2) and remove.

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Installation:

Check contact surface (1) on the exhaust turbocharger for contamination and clean it if necessary.

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Push in control rod (1) carefully in the direction of the arrow up to the limit position on electrical wastegate valve controller (2).

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Determine dimension (A) of control rod (1) of electrical wastegate valve controller (2) with a commercially available caliper gauge (3).

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Add dimension (B) on control rod (1) of electrical wastegate valve controller (2) with a commercially available caliper gauge (3) to dimension (A).

Dimension (B) = 4.5 mm

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Feed in adjusting nut (1) in direction of arrow up to limit position on control rod (2) and install.

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Install electrical controller drive (2) and position it correctly.

Tighten screws (1).

Tightening torque 11 65 3AZ .

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Carefully push the lever (1) of the wastegate valve in direction of arrow onto the control rod as far as it will go.

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Replace lock nut (1).

Parts: Attachment nut

Feed in new lock nut (1) and install.

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Fit new lock nut (1) and adjusting nut (2) on lever (3) of wastegate valve.

Tighten new lock nut (1) and adjusting nut (2) hand-tight.

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Attach and lock connector (1).

Connector (1) must snap audibly into place.

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Checking of the wastegate linkage end stops only possible with diagnosis.

Diagnosis path: Service functions -> Drivetrain -> Engine electronics -> Adjustment functions -> Check wastegate linkage end stops.

CAUTION: Lock nut (4) must be tightened with two open-end spanners. If only one open-end spanner is used, there is a risk of the electrical controller drive being damaged.

Counter-hold adjusting nut (3) with the sanded commercially available open-ended spanner (2).

Tighten lock nut (4) with a standard open-end spanner (1).

Tightening torque: 11 65 4AZ .

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Required follow-up work:

Install CLEANING AIR PIPE .