I originally posted this in a different thread but decided to start a new one to make searching easier.

I recently bought a 2012 Countryman All4 that had a boost problem with 2C57 and 2CD3 codes. I applied 15" vacuum to the actuator and could see the gate moving but it was jerky and sticking. I pulled the O2 sensor and used a borescope to watch the wastegate to see if it was sealing properly. The wastegate was totally gone and was sitting on the Cat honeycomb. I found a used turbo from a 2008 Cooper S (N14) and will start the replacement next week. I will post additional picture once I have the turbo removed and I recover the wastegate from the cat.

 

I managed to get the wastegate out of the catalytic converter. It looks like it simply snapped at the pivot point. Obviously had to be a defect. There really isn't any real force on the wastegate, other than air pressure, but that shouldn't be enough to snap the gate.

 

I am flabbergasted to see that flap completely broken off like that I think this is the first time I've seen that happen. Usually, the pivot wears down in the housing, causing the flapper not to seal correctly. But, I've never heard of the flap just breaking right off.

 

I agree. I can't think of any reason that it would have snapped. Possibly damaged before the engine was assembled.

 

I removed the old wastegate flapper and pressed out the bushing then pressed in a new bushing and installed the new flapper and welded the pin. The weld isn't the prettiest but it is solid.