11 37 014 Removing and installing/replacing right intermediate lever (N62 from 9/03): Installation

WARNING: This page is about a different variant/trim than selected.

Removal of intermediate levers is described separately from installation.

Clean all bearings and cams of inlet camshaft and lubricate with engine oil.

IMPORTANT: Intermediate levers (2) are divided into individual tolerance classes.
Only intermediate levers of the same tolerance class may be fitted in a single cylinder head.
The tolerance classes are designated as illustrated with the numbers from 1 to 5.
Used intermediate levers (2) may only be reused in the same position.

Lubricate all sliding surfaces on intermediate lever (2) with engine oil.

Fig 1: Identifying Intermediate Levers

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Raise torsion spring (1) with special tool 11 9 480.

Detach special tool 11 9 490.

Fig 2: Raising Torsion Spring With Special Tool 11 9 480

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Hold torsion spring (1) with special tool 11 9 480.

Install intermediate lever (2) from above.

Insert end of torsion spring (1) into guide on intermediate lever (2).

Fig 3: Holding Torsion Spring With Special Tool 11 9 480

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Raise second end of torsion spring with special tool 11 9 480.

Detach special tool 11 9 490.

Fig 4: Raising Second End Of Torsion Spring With Special Tool 11 9 480

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Hold torsion spring (1) with special tool 11 9 480.

Install intermediate lever (2) from above.

Insert end of torsion spring (1) into guide on intermediate lever (2).

Fig 5: Inserting End Of Torsion Spring Into Guide On Intermediate Lever

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Remove special tool 11 9 474.

Fig 6: Removing Special Tool 11 9 474

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Remove special tools 11 9 472 and special tools 11 9 475.

Fig 7: Removing Special Tools 11 9 472 And 11 9 475

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Ends of compression rings (1) point upwards.

Make sure compression rings (1) are engaged at ends.

Fig 8: Installing Compression Rings

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IMPORTANT: Rocker arms (1) slip slightly when bearing bracket is fitted.

Make sure rocker arms (1) are secured as illustrated on hydraulic valve clearance compensating elements and on valves.

Align rocker arms (1) straight.

Fig 9: Securing Rocker Arms On Hydraulic Valve Clearance Compensating Elements

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Remove special tool 11 9 473.

Remove bearing bracket (1) from special tool 11 9 470.

Fig 10: Removing Bearing Bracket From Special Tool 11 9 470

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IMPORTANT: Do not tilt bearing bracket (1).

Lower bearing bracket (1) from above and carefully bring into contact with cylinder head.

Insert nuts and tighten by hand without play.

IMPORTANT: Make sure none of the intermediate levers or rocker arms have slipped out.

Tighten down nuts from inside to outside.

Tightening torque, see ENGINE - TIGHTENING TORQUES .

Fig 11: Tightening Bearing Bracket Nuts

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IMPORTANT: Do not mix up the camshaft bearing covers of cylinders 1 to 4 and 5 to 8.

Fit bearing cap L E1 in such a way that marking is legible from inlet side.

Install nuts and tighten down.

Tightening torque, see ENGINE - TIGHTENING TORQUES .

Fig 12: Fitting Bearing Cap L E1

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Rotate inlet camshaft at hexagon head against direction of rotation until cam on 1st cylinder points downwards at an angle as shown in illustration.

NOTE: The marking (1) on the hexagon drive of the inlet camshaft faces upwards.

Fig 13: Identifying Marking On Hexagon Drive Of Inlet Camshaft

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Install inlet and exhaust adjustment unit on right side.

Install spark plugs on cylinder bank 1 to 4.

Install right cylinder head cover.

Install ignition coils on cylinder bank 1 to 4. See IGNITION COIL .

Install servomotor for right eccentric shaft.

Assemble engine.