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      04-21-2017, 02:26 AM   #1
JMX6V8
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Parts from Wastegate Actuator inside Charge-air cooler N63 Engine

Well after a long road trip (3K miles) from Ohio to San Antonio TX, my beast had an engine malfunction message, code 2A7E. Three months ago I had another malfunction message and it was for a faulty ignition coil. That was a 15 minutes DIY. The bad news is that it is not as simple as changing of the ignition coil. The DIY started as a Bank2 VANOS solenoid valve replacement, but it turned out to be a little more, see picture 2. I am posting this here now to see if anyone has seen anything like this before. I found parts from the Wastegate Actuator (Pic 3) inside one of the charge-air cooler. It is very easy to check if your Wastegate Actuator’s parts are inside your charge-air cooler. Remove one of the Air hose (Pic 8) coming from the Turbo charger and insert a magnet inside the cooler. Remember, this is not the reason why I got the engine malfunction light. After inspecting the Wastegate Actuators, they seem to have been broken for a while. Once I saw the parts inside one of the charge-air cooler, I decided to check the other cooler, and sure enough, the same parts were inside of it as well. Picture 4 and 5 shows the actual part that I needed to change. I am still waiting for all the parts including two new Wastegate Actuator and also two new camshaft sensor, just in case. Now, back to the Wastegate Actuator job. This was not an easy DIY. It took me two trips to the auto store and a whole day to figure out the way to remove them. 3 Torx bolts hold them. The first two are easy to get, but it is durable. The bottom bolt is impossible to get out without taking the whole Charger off(Pic 6). It was not until I was just so upset that pull on one of them and it just broke (disintegrated) from the bolt. At that time, I was able to get to the last bolt. I broke the second off and took the last bolt out. To put them back, I am not using the same type of screws. I am using one that I can turn with an open end wrench. Part number 07119904524 is the same size and fit (Pic 7).

Picture 1 is the message I received from ISTA, 2A7E.

Picture 2 is the Turbo charge-air cooler with part inside

Picture 3 are the Wastegate Actuators

Picture 4 is the VANOS solenoid valve that needs to be replaced.

Picture 5 is the location of the bank2 VANOS solenoid valve.

Picture 6 is the location of the Wastegate actuators and the impossible bolts (marked by the red line)

Picture 7 is the bolts I am using to replace the unreachable bolts.

Keep in mind, I am still waiting on parts and have not attempted to put everything together. More to follow.
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Last edited by JMX6V8; 04-21-2017 at 02:33 AM..
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      04-22-2017, 06:49 AM   #2
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I'm not quite sure how a piece that big can make it thru the air track. So did that piece go thru the wastegate or ?

As I fellow N63 owner hope this goes back together well for you.
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      04-23-2017, 08:31 AM   #3
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It doesn't have to travel that far! It is part of the Wastegate. If you look at the picture, it goes from the top opening of the turbos (the valve is attached to the left side of the turbo) to the air hose(#4) into the charge-air cooler.



I received all my parts Friday afternoon. I was going to write a DIY for it, but I didn't see much interest on the subject so I just put everything together. Everything is working great again. I erased all the fault codes, ran ISTA again, and I have all green lights . I can feel the turbos getting more pressure and faster response. According to a description on ESC Tuning, the Wastegate actuator releases excess boost pressure. A failed unit may result in a boost leak, reduced performance, and, ultimately, turbocharger failure.

I drove the X6 for over 50 miles, pushing it to the floor. No more limp mode after fast acceleration!
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      05-02-2017, 12:30 AM   #4
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thanks for the write up.

too late for the DIY write up? I'm having some issues with my turbos apparently as well....
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      05-02-2017, 11:49 AM   #5
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Quote:
Originally Posted by vic7780 View Post
thanks for the write up.

too late for the DIY write up? I'm having some issues with my turbos apparently as well....
Vic,

I was going to put everything in a pdf/word document, but I saw that there wasn't much interest in the subject so I didn't waste my time. The steps are in my initial post. What kind of issues are you having? I will help the best I can.
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      05-02-2017, 11:57 AM   #6
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looking at the DV's design, it either had a catastrophic failure (there is a black plastic part that presses against the charge tube, which prevents the inner solenoid assembly from going into the charge tube), or when someone worked on your car previously, the "black plastic part" from the DV was not left out.

Once you get a new DV and inspect it, you will know what i mean.
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      05-02-2017, 12:51 PM   #7
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I think they both had a catastrophic failure. The plastic part was torn up. They have never being changed and the new design look different.
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      05-06-2017, 03:14 PM   #8
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Quote:
Originally Posted by JMX6V8 View Post
I think they both had a catastrophic failure. The plastic part was torn up. They have never being changed and the new design look different.
ahh got it, thanks for sharing this with us btw!
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      05-07-2017, 03:03 AM   #9
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That's just crazy, glad you got it fixed.
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      05-07-2017, 03:12 AM   #10
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Quote:
Originally Posted by godmans View Post
ahh got it, thanks for sharing this with us btw!
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      05-07-2017, 03:14 AM   #11
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Quote:
Originally Posted by m5james View Post
That's just crazy, glad you got it fixed.
I know!, thanks.
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