11 65 803 Removing and installing/replacing wastegate valve controller (production date up to 06/2019)

WARNING: This page is about a different variant/trim than selected.

Special tools required:

2 469 240

WARNING: Risk of burning!
Carry out this repair only on an exhaust turbocharger which has been cooled down .

CAUTION: Read and comply with NOTES ON PROTECTION AGAINST ELECTROSTATIC DISCHARGE (ESD PROTECTION) .

NOTE: From the version of 02/2016 the exhaust turbocharger and the "Electrical wastegate valve controller" repair package have been changed.
For vehicles of a version up to 01/2016 , the electrical controller drive with the part number 8 660 987 , must be ordered and used.
For vehicles of version starting from 02/2016 , the electrical controller drive with part number 7 850 453 and heat shield 8 671 960 must be ordered and used.

Necessary preliminary work:

Remove the REAR COWL PANEL COVER .
Remove the FRONT OXYGEN SENSOR .
Remove the MONITORING OXYGEN SENSOR .
Remove the FRONT RIGHT WHEEL .

Removal:

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Overview of electrical wastegate valve controller of version starting from 02/2016 .

CAUTION: When removing electrical controller drive (1) of the wastegate valve, ensure that any lateral forces acting on the control rod are avoided when removing the control rod on the lever of the wastegate valve. (Risk: Preliminary damage of the electrical controller drive.)

Have special tool 2 469 240 ready.

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Release screws (1) on left heat shield (3).

Feed out and remove the left heat shield (3) from the guide pin (2).

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Release screws (1) on upper heat shield.

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Release screw (1) on upper heat shield (2).

Feed out and remove upper heat shield (2).

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Close exhaust turbocharger (2) with standard tools (1).

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Unlock and disconnect plugs (1).

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CAUTION: Release the lock nut using two open-end spanners . If only one open-end spanner is used, there is a risk of the electrical controller drive being damaged .
Grip adjusting nut (1) with a standard opened spanner (2).
Release lock nut (3) with a standard open-end spanner (4).

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Pull out and remove nut (1).

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Feed the lever (1) of the wastegate valve carefully in the direction of the arrow out of the control rod (2) of the electrical wastegate valve controller and place to one side.

Avoid any lateral forces on control rod (2) of the electrical wastegate valve controller.

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Determine dimension (A) of the adjusting nut (1) with a commercially available tool.

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Release screws (1).

Pull out and remove electrical wastegate valve controller (2) with the heat shield carefully from the bore hole of the compressor housing.

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Installation:

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Overview of the electrical wastegate valve controller of version from 02/2016 .

For vehicles of version starting from 02/2016 , the electrical controller drive with part number 7 850 453 and heat shield 8 671 960 must be ordered and used.

CAUTION: When installing electrical controller drive (1) of the wastegate valve, ensure that any lateral forces acting on the control rod are avoided when installing the control rod on the wastegate valve lever. (Risk: Preliminary damage of the electrical controller drive.)

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

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Replace heat shield (1).

Parts: Heat shield

Guide and install new heat shield (1) on housing (2) of the exhaust turbocharger.

Ensure that the new heat shield (1) is positioned correctly on housing (2) of the exhaust turbocharger in the marked areas.

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Guide and position electrical wastegate valve controller (2) in the bore hole of the compressor housing.

Ensure that the heat shield is positioned correctly on the compressor housing.

Replace screws (1).

Parts: Bolts

Tighten new screws (1).

Tightening torque 11 65 3AZ .

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Replace adjusting nut (1).

Parts: Adjusting nut

Adjust new adjusting nut (1) to the dimension (A) that has been determined.

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Push lever (1) of the wastegate valve carefully onto control rod (2) up to the limit position in the direction of the arrow and fit it.

Avoid any lateral forces on control rod (2).

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Replace lock nut (1).

Parts: Attachment nut

Fit new lock nut (1) in lever (2) of the wastegate valve.

Tighten lock nut (1) until hand-tight.

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Attach and lock connector (1).

Make sure the connector (1) engages audibly.

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Pull out and remove standard tool (1) from exhaust turbocharger (2).

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NOTE: Basic setting of the wastegate linkage can only be checked or adjusted through diagnosis .
Diagnosis path: Adjust the service functions -> drive -> DME -> adjustment functions -> wastegate linkage.

CAUTION: Tightening adjusting nut (2) and lock nut (1) is permitted only with the use of two open-end spanners .
Using just one open-end spanner poses risk of damage to the electrical controller drive.

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NOTE: Shorten adjustment travel (-).
Increase adjustment travel (+).
The adjusting nut must be indicated with a colored mark to set the adjustment travel safely.
One full turn of the adjusting nut corresponds to an adjustment travel of 0.75 mm .
Example 1:
Actual value measured by the diagnostic function: +0.75 mm .
Required correction: +0.75 mm: 0.75 mm = +1.0 turns.
Adjust adjusting nut (2) by 1.0 revolutions in the direction of the positive terminal and then tighten lock nut (1).
Tightening torque 11 65 4AZ .
Example 2:
Actual value measured by the diagnostic function: -1.5 mm .
Required correction: -1.5 mm: 0.75 mm = -2 turns.
Adjust adjusting nut (2) by 2 revolutions in the direction of the negative terminal and then tighten lock nut (1).
Tightening torque 11 65 4AZ .
Check basic setting again using diagnosis.

Check that the wastegate valve linkage has no play.

Guide heat shield (1) on the exhaust turbocharger at the top and install.

Ensure that heat shield (1) is positioned correctly on heat shield (2).

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Feed in upper heat shield (2) and secure with screw (1).

NOTE: Join all screws of the heat shield first and tighten them afterwards.
Tightening torque 18 30 8AZ .

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Secure upper heat shield with screws (1).

NOTE: Join all screws of the heat shield first and tighten them afterwards.
Tightening torque 18 30 8AZ .

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Feed in left heat shield (3) and secure at the guide pin (2).

Join and tighten screws (1).

Tightening torque 18 30 8AZ .

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Required follow-up work:

Install the FRONT OXYGEN SENSOR .
Install the MONITORING OXYGEN SENSOR .
Install the REAR COWL PANEL COVER .
Fit FRONT RIGHT WHEEL .