Installing electrical wastegate valve controller for the exhaust 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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Detach control rod (1) of the electrical wastegate valve controller (3) carefully from the pin on the lever of 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 in the arrow direction 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 TORQUE SPECIFICATIONS

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 exhaust turbocharger for contamination and clean if necessary.

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Guide the electrical wastegate valve controller (1) into the bore of the compressor housing in the arrow direction and position it.
Install control rod (2) of the electrical wastegate valve controller (1) carefully on the lever of wastegate valve controller (3) .
In the process, any effect of lateral force on the control rod (2) 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 TORQUE SPECIFICATIONS

Electrical controller drive to exhaust 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 RIGHT INTAKE PORT .
Refer to INSTALLING THE CLEAN AIR PIPE FOR CYLINDERS 4-6 .
Refer to INSTALLING THE RIGHT INTAKE FILTER HOUSING (FRONT-END STRUT REMOVED) .
Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
Refer to INSTALLING UPPER CROSS CONNECTION .
Refer to INSTALLING THE CENTER ENGINE COMPARTMENT COVER .
Refer to INSTALLING THE FRONT HOOD SEAL .
Refer to INSTALLING THE FRONT-END STRUT .