Installing electrical wastegate valve controller for the turbocharger (cylinders 1 to 3)

Repair kit for the electric wastegate valve controller

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NOTE: RISK OF DAMAGE
Damage to the electrical controller drive and the mechanical connection.
Improper handling of the electrical controller drive can lead to malfunctions or failure of the electrical controller drive.

Do not release the screw connection between the wastegate linkage and the control rod on the wastegate valve controller and do not twist it.
Avoid exposure of lateral forces to the control rod of the electrical controller drive.
Remove all the screws on the electrical controller drive before the control rod on the wastegate linkage is detached.

Slide the control rod (1) carefully in the arrow direction up to the stop on the electrical wastegate valve controller (2) .

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

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Supplement dimension (B) on the control rod (1) of the electrical wastegate valve controller (2) with a commercially available caliper gauge (3) to dimension (A) .
Dimension (B) = 3.5 mm

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Screw on the nut (1) in the arrow direction up to the stop on the control rod (2) .

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Feed in the electrical wastegate valve controller (1) in the arrow direction and install it.
Hand-tighten the screws (2) .

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Feed in and position the lever (1) carefully on the pin (2) .

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Feed in the cotter pin (1) using standard pliers (2) in the arrow direction and install it.

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Slide in the lever (1) of the wastegate valve carefully in the arrow direction up to the stop.
Hand-tighten the adjustment nut (2) on the lever (1) .

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Feed in lock nut (1) and install.

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NOTE: TECHNICAL INFORMATION
The adjustment nuts must be locked using 2 open-end wrenches. If only one open-end wrench is used, there is a risk of the electrical controller drive being damaged.
Hold the adjustment nut (2) with a standard open-end wrench (3) .
Tighten the attachment nut (1) with a standard open-end wrench (3) .

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Guide out the cotter pin (1) in the arrow direction using standard pliers (2) and remove it.

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Release the screws (2) on the electrical wastegate valve controller (1) .

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Carefully detach the control rack (1) of the electric wastegate valve actuator (3) from the pin on the lever of the wastegate valve (2) .
In the process, any effect of lateral force on the control rod (1) is to be avoided.
Guide out the electrical wastegate valve controller (3) from the bore of the compressor housing and remove it.

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Have the following tools ready:

Number	Description
1	Open-end wrench (key range 10-11)
2	Torque wrench
3	Socket (key range 11)

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Hold the adjustment nut (2) with a standard open-end wrench (3) .
Tighten the attachment nut (1) with a standard torque wrench (4) .

TIGHTENING TORQUES SPECIFICATION

Control rod for electric wastegate valve controller
M6 Only use an open-end wrench (for counter support) to tighten the lock nut!	tightening torque	6 ± 0.3 Nm

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Check the contact surface (1) at the turbocharger for contamination and clean if necessary.

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Guide the electrical wastegate valve controller (3) into the bore of the compressor housing and position it.
Carefully mount the control rod (1) of the electric wastegate valve controller (3) on the lever of the wastegate valve (2) .
In the process, any effect of lateral force on the control rod (1) is to be avoided.

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Replace screws (1) .
Parts: Screws

The screws are included in the repair kit.
Tighten the screws (1) in a crosswise pattern using the special tool 2 469 240 .

TIGHTENING TORQUES SPECIFICATION

Electrical controller drive to turbocharger
M4 Replace screws. Tighten screws crosswise.	tightening torque	2 Nm

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Replace cotter pin (1) .
Parts: Cotter pin

The cotter pin is included in the repair kit.
Feed in the cotter pin (1) using standard pliers (2) in the arrow direction and install it.
Ensure that the retaining clip (1) engages audibly.

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Check the ability to move of the lever (1) .
It must be possible to move the lever (1) in the arrow direction without applying excessive force.

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Connect connectors (1) and lock.
The connector (1) must engage audibly.

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Follow-up work

Refer to FOR ELECTRICAL WASTEGATE VALVE CONTROLLER: TEACHING IN AND CHECKING END STOPS WITH THE DIAGNOSTIC SYSTEM (AFTER VEHICLE DIAGNOSIS) .
Refer to INSTALLING THE HEAT SHIELD ON THE TURBOCHARGER FOR THE CYLINDERS 1 TO 3 .
Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
Refer to INSTALLING FRONT CROSS CONNECTION .
Refer to INSTALLING FRONT-END STRUT ON LEFT AND RIGHT .
Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT AT TOP LEFT AND RIGHT .
Refer to INSTALLING INTAKE FILTER HOUSING .
Refer to INSTALLING THE STRUT BRACE .
Refer to INSTALLING MOUNT OF HOOD SEAL ON THE LEFT AND RIGHT .
Refer to INSTALLING THE REAR RIGHT ENGINE COMPARTMENT COVER .
Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT ON THE REAR LEFT .