E60 Diesel: Replace Turbo Waste-Gate [Actuator]

This is a pretty easy job and can be done with removing the turbo, exhaust-manifold or rocker cover.

1. Remove the inlet duct to the air-filter housing. It's held by a T30-Torx screw at the front and just unclips from the housing.
2. Remove the boost-pipe from the top of the turbo by removing the screw from the left side of where it joins to the turbo using a 10mm wrench, then loosening the right hand screw using a T30-Torx socket and rotating the collar clockwise until it can be pulled out of the turbo.
3. Remove the other end of the boost-pipe from the left side of the intercooler by reaching from underneath with a flathead screwdriver and sliding the metal clip down. The pipe should pop the intercooler easily and be pulled out from above. [This can be done without fully removing the engine-undertrays].
4. Gently slide the rubber vacuum-hose off the metal spout on the waste-gate.
5. Remove the three screws holding the waste-gate to the turbo using a 10mm wrench. [There is just enough room down the left side of the engine to get a ring-spanner on, otherwise a ratchet with a short extension-bar may get them more easily].
6. Push a cloth or some tissue roll down under the bottom of the waste-gate between the turbo inlet and exhaust wheels to stop the retaining-clip getting lost into the engine and slide the clip off the waste-gate arm using a long flat screwdriver. [There is just enough clearance to get an angle with the screwdriver and just about see the clip. The clip will probably have to be removed with a stick-magnet].
7. Slide the waste-gate arm off the stud and remove it.
8. Refit the new waste-gate as a reversal of above, being careful not to lose the retaining-clip during refitting. The clip may need holding in position with a stick-magnet as it is pushed down with a flat screwdriver.