So my darling wife recently got herself a 2012 Countryman 4all S. Which we all know means we as the devoted husbands have to work on them. Her car started going into 1/2 power mode due to low charge pressure. After looking around here and other forums i deduced it was a failed turbo wastegate. ordered a new Borg Warner turbo and install kit from FCP Euro and had a grand old time replacing the turbo. Upon inspecting the old wastegate flap, it seemed to be cracked near the hinge portion and would not close and cover to opening. Diagnosis confirmed. put the new turbo in and put the front end back on. Upon startup i found that I had not tightened the lower banjo bolt for the oil feed line, so it all came apart again.

Now its back together and running well. dang thing is peppier that i expected actually. I plugged in my BimmerGeeks ProTool and started watching live data for coolant temp, Boost and a couple other things. I've noticed that when I floor it the thing is hitting 20PSI of boost! reading here and elsewhere on the good Old Google I see 8 - 10 is normal, and 13PSi is "Over boost". Ummmm..... Yea, I think I'm way past that. How do I bring the boost level back down to a sane level? They previous owner fitted a larger intercooler to the front, but I don't see that upping the boost... What do i need to look at on this thing? My wife wants her car back, but im concerned that it may be dangerous for the motor to be seeing 20PSI.

 

How long after purchase did you have to change out the turbo? If an aftermarket intercooler was fitted, it’s possible it was loaded with an aftermarket tune. 20 psi isn’t that bad, as long as the tune is loaded to allow for it.

 

Previous owner said that it wasnt tuned. Should be stock. I know he had the larger intercooler installed, and he changed the exhaust to a straight pipe. Totally sounded like A$$... Tonight after work Im going to try adjusting the wastegate valve a bit and see what that does. With the old turbo we saw 9-13 pounds of boost. Now with the new one we are seeing 20. Talking with FCP Euro where I bought the turbo they suggested teh wastegate actuator may be adjusted wrong. So I get to pull the front off this thing for a third time to try that.

 

Well, i just pulled the O2 sensor and upper heat shield. was then able to get a socket and extension on the lock nut for the wastegate actuator rod and loosened it one turn then tightened the inner nut with a wrench. Boost level is now down to a peak of 15 psi when i floor it. I may try moving it a touch more when it cools off.

 

I have a JCW R60 with a dying turbo I'm just now starting to shop around for ideas on what to do. Can you estimate how long you think it took you to replace it?

 

Ditto, 2012 Countryman S, 65k miles.

 

I posted this reply in the wrong thread and don't know how to delete it, sorry.