11 65 803 Removing and installing/replacing electrical controller drive for wastegate valve (Countryman S FWD, Countryman S ALL4 AWD)

Removal:

Special tools required:

2 469 240

WARNING: Risk of burning! Only perform this repair on the exhaust turbocharger when it has cooled down.

IMPORTANT: Read and comply with notes on PROTECTION AGAINST ELECTROSTATIC DISCHARGE (ESD PROTECTION) .

NOTE:

For vehicles with production date after 02/2016, the electrical controller drive with the part number 7 850 453 and the heat protection 8 671 960 must be ordered and used.

Necessary preliminary tasks:

Overview of electrical wastegate valve controller:

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1. Electrical wastegate valve actuator

2. Screws

3. Heat shield

4. Adjustment nut

5. Attachment nut

IMPORTANT: When removing the electrical controller drive (1) of the wastegate valve, make sure that any lateral force on the control rod is prevented when removing the control rod on the lever of the wastegate valve. (Risk: Prior damage of the electrical controller drive. )

Have the special tool 2 469 240 ready.

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

Release left heat shield (3) from guide pin (2) and remove.

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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 connector (1) and pull off.

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The attachment nut must be released with two open-end wrenches . If only one open-end wrench is used, there is the risk of damaging the electrical controller drive.

Counter support the adjustment nut (1) with a standard open-end wrench (2).

Release attachment nut (3) with a standard open-end wrench (4).

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Unthread and remove the attachment nut (1).

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Guide out the lever (1) of the wastegate valve from the control rod (2) of the electrical wastegate valve controller carefully in the arrow direction and set aside.

Any effect of lateral force on the control rod (2) of the electrical wastegate valve controller must be avoided.

Guide out and remove the adjustment nut (1) in the arrow direction .

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Release the screws (1).

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

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Unlock clamp (1) and detach it at top.

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Installation:

Install in the reverse order of removal.

Installation notes:

Check the contact surface on the exhaust turbocharger for contamination and clean if necessary.

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Replace heat shield (1). Guide new heat shield (1) into the housing (2) of the exhaust turbocharger and install. Make sure that the new heat shield (1) is positioned correctly in the marked areas on the housing (2) of the exhaust turbocharger.

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Slide the control rod (1) carefully in the arrow direction all the way 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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Add dimension (B) on the control rod (1) of the electrical wastegate valve controller (2) to dimension (A) with a commercially available caliper gauge (3). Dimension (B) = 4.5 mm

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Tightening torque for wastegate valve actuator drive to exhaust turbocharger:
M4 screw with washer: 2.5 ± 0.5 Nm

M4 screw without washer: 1.9 ± 0.2 Nm
Use new adjustment nut and new attachment nut.
Slide the lever of the wastegate valve carefully onto the control rod, all the way to the stop, and bring it into contact. In the process, any effect of lateral force on the control rod must be avoided.
The attachment nut must be tightened with two open-end wrenches . If only one open-end wrench is used, there is the risk of damaging the electrical controller drive.
Counter support the adjustment nut with a standard open-end wrench. Tighten the attachment nut with a standard open-end wrench. Tightening torque: 6 ± 0.3 Nm

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1. Electrical wastegate valve actuator

2. Screws

3. Heat shield

4. Adjustment nut

5. Attachment nut

NOTE:

The end stops of the wastegate linkage can be checked only using the appropriate diagnostic scan tool.

Diagnosis path: Service functions -> Drivetrain -> Digital Motor Electronics -> Adjustment programs -> Check wastegate linkage end stops.

Required follow-up work: