Wastegate Actuator: Service and Repair

REPLACING BOOST PRESSURE CONTROL VALVE PRESSURE SERVO

Special Tools: 998 5496, 999 5230, 999 5544





Preparations

Remove:
- Turbocharger (TC) heat shield.





Removing Pressure Servo

Remove:
- Boost Pressure Control (BPC) Valve spindle lock pin.
- Turbocharger (TC) control valve hose.
- Fresh air hose from turbocharger (TC) and Mass Air Flow (MAF) Sensor and move to one side.

NOTE! Remove the following in the order specified.

- Rear pressure servo screw (1)
- Front pressure servo screw (2).

Installation of Pressure Servo

Install:
- New pressure servo.
- Screws and tighten to 20 Nm (14.76 ft.lb.).





Basic Adjustment of Pushrod

- Connect manometer 999 5230 and pressure tester 998 5496 to pressure servo.
- Pump up pressure to 18 ± 1 kPa (2.56 ± 0.14 psi).
- Push boost pressure control (BPC) valve spindle towards turbocharger (TC) housing (closed valve).
- Adjust push rod so that it fits onto spindle lug exactly.
- Install lock pin to boost pressure control (BPC) valve spindle.
- Tighten pushrod locknut.
- Remove manometer and pressure tester.

NOTE! Push rod must not be twisted during adjustment, otherwise pressure servo diaphragm may be damaged.

Reinstall

Install:
- Hose on turbocharger (TC) control valve.
- Fresh air intake between turbocharger (TC) and mass air flow (MAF) sensor.
- Heat deflector plate.