11 37 010 Removing And Installing/Replacing Intermediate Levers (N51)

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Special tools required:

For the following special tools, refer to ENGINE - SPECIAL TOOLS (N51) .

11 4 270
11 4 450
11 4 481
11 7 110

IMPORTANT: Aluminum-magnesium materials. No steel screws/bolts may be used due to the threat of electrochemical corrosion. A magnesium crankcase requires aluminum screws/bolts exclusively. Aluminum screws/bolts must be replaced each time they are released . Aluminum screws/bolts are permitted with and without color coding (blue). For reliable identification: Aluminum screws/bolts are not magnetic . Jointing torque and angle of rotation must be observed without fail (risk of damage) .

NOTE: There are 2 different versions of the gate

IMPORTANT:

Establish size of gates.

Version 1

Size 55.2 mm

Version 2

Size 58 mm

Version 1 Size (1) 55.2 mm

Necessary preliminary tasks:

Remove CYLINDER HEAD COVER (N51) .

Fig 1: Identifying Guide Block Dimension

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If necessary, set eccentric shaft (1) on twin surface to minimum lift (2).

Fig 2: Setting Eccentric Shaft On Twin Surface To Minimum Lift

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Secure special tool 11 4 270 with gripping pliers (3) to guide block (2).

IMPORTANT: Special tool 11 4 270 is only secured to guide block. Adjusting the gripping pliers (3) is not permitted (risk of damage) on special tool 11 4 270.

NOTE: The oil nozzle must be removed beforehand from cylinder no. 3.

Fig 3: Identifying Special Tools

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WARNING: Risk of injury in event of incorrect use.

IMPORTANT: Incorrect handling - risk of damage!

Secure both bearing pins (2) in return spring with knurled screw (1) on special tool 11 4 270.

Press special tool 11 4 270 in direction of arrow as far as it will go.

Fig 4: Securing Both Bearing Pins In Return Spring With Knurled Screw On Special Tool

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Release steel screw (2).

To avoid jamming with screw (2) and return spring, it is necessary when releasing screw (2) to relieve the pretension on special tool 11 4 270 uniformly.

IMPORTANT: Risk of damage to cylinder head thread.

Tightening torque. See 11 37 2AZ .

Fig 5: Identifying Steel Screw

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Relieve tension on return spring (1) with special tool 11 4 270.

NOTE: Metal lug (2) cannot be disassembled and must not be removed.

Installation:

Replace metal lug if tab washer is defective.

Fig 6: Identifying Return Spring And Metal Lugs

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Press return spring apart at position (1) and remove towards top.

Fig 7: Removing Return Spring

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IMPORTANT: Uniform distribution must not be changed.
All components must be set down in a clean and orderly fashion.

All components must be reinstalled in the same positions in an engine which has already been in use.

Fig 8: Identifying Special Tool

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Eccentric shaft with bearing
Bearing caps of eccentric shaft set out in order.
Inlet camshaft
Bearing caps of inlet camshaft set out in order.
Intake valves with valve springs
Valve plates and valve cotters
Roller cam followers with HVC element set out in order.
Return springs.
Guide blocks set out in order.
Intermediate levers set out in order.

Release screws (1).

Tightening torque. See 11 37 1AZ in 11 37 VARIABLE VALVE GEAR .

Set down guide blocks (2) in special tool 11 4 481 in neat order.

Installation:

Mixing up the guide blocks may cause the engine to demonstrate idle fluctuations.

This will result in maladjustment of uniform distribution.

Fig 9: Identifying Screws And Guide Blocks

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Installation:

Contact surfaces (1) must be clean and oil-free.

Clean if necessary.

Fig 10: Identifying Contact Surface

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Lift out intermediate levers (2).

Intermediate levers (2) set out in special tool 11 4 481 in order.

Installation:

Mixing up the intermediate levers may cause the engine to demonstrate RPM fluctuations.

Installation:

Contact surfaces (1) must be clean and oil-free.

Clean if necessary.

Fig 11: Identifying Contact Surface And Intermediate Levers

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All intermediate levers (1) are classified.

Reinstall intermediate levers which have already been used in the same positions.

Fig 12: Locating Marking On Intermediate Levers

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Installation:

Before reinstalling the intermediate levers, make sure the roller cam followers are correctly positioned (risk of damage).

Install intermediate levers (2).

Fig 13: Identifying Contact Surfaces And Intermediate Levers

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Fit guide block (2) cleanly into opening.

Tighten screws (1) hand-tight.

Check both intermediate levers again to ensure correct installation position.

Release bolts (1) again by a 1/4 turn.

Fig 14: Identifying Guide Block With Bolts

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Secure special tool 11 4 450 DEVICE to bolt connection (1) of eccentric shaft.

Turn eccentric lever (3) on special tool 11 4 450 DEVICE in direction of arrow.

Guide block is now tensioned.

Secure screws (2).

Tightening torque: 11 37 1AZ .

Installation:

At cylinder no. 3, the guide block can be preinstalled with one bolt (2) only.

Fit oil pump only after retaining spring has been fitted.

Fig 15: Turning Eccentric Lever

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Fit return spring on guide block.

Installation:

Insert return spring (2) in intermediate lever (1) (see arrow).

Check roller cam follow (3) again to ensure correct installation position.

Fig 16: Inserting Torsion Spring In Intermediate Lever

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Secure special tool 11 4 270 DEVICE with gripping pliers (3) to guide block (1).

IMPORTANT: Special tool 11 4 270 DEVICE is only secured to guide block.
Adjusting the gripping pliers (3) is not permitted (risk of damage) on special tool 11 4 270 DEVICE .

Fig 17: Identifying Gripping Pliers, Guide Block And Special Tool (11 4 270)

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WARNING: Risk of injury in event of incorrect use.

IMPORTANT: Incorrect handling risk of damage.

Secure both bearing pins (2) in return spring with knurled screw (1) on special tool 11 4 270 DEVICE .

IMPORTANT: Check return spring again on intermediate lever to ensure correct installation position.

Press special tool 11 4 270 DEVICE in direction of arrow as far as it will go.

Fig 18: Pressing Special Tool (11 4 270)

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Insert steel screw (2).

To avoid jamming with screw (2) and return spring, it is necessary when inserting screw (2) to increase the pretension on special tool 11 4 270 DEVICE uniformly.

IMPORTANT: Risk of damage to cylinder head thread.

Tightening torque: 11 37 2AZ .

Remove special tool 11 4 270 DEVICE .

Fig 19: Inserting Steel Screw

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At cylinder no. 3, adjust oil nozzle (2) so that oil spray (3) points precisely towards spline teeth.

Fig 20: Identifying Oil Spray Nozzle With Spray

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Assemble engine.

Version 2

Size (1) 58 mm

Fig 21: Identifying Guide Block Dimension

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Remove CYLINDER HEAD COVER (N51)

If necessary, move eccentric shaft (1) on twin surface to minimum lift (2).

Fig 22: Moving Eccentric Shaft

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NOTE: Oil spray nozzle must be removed from 3rd cylinder (make a note of installation position of oil spray nozzle).

Fig 23: Identifying Oil Spray Nozzle With Spray

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Position special tool 11 7 110 on return spring (1) (see arrows).

Fig 24: Positioning Special Tool (11 7 110) On Return Spring

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WARNING: Risk of injury in event of incorrect use.

IMPORTANT: Improper handling. Risk of damage!

Place special tool 11 7 110 flat on cylinder head.

Turn knurled screw (1) in direction of arrow until both clamping levers secure return spring in guide block.

Fig 25: Turning Knurled Screw

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Return spring is correctly preloaded when both clamping levers are parallel to guide block.

Fig 26: Identifying Special Tool (11 7 110)

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IMPORTANT: Risk of damage!

Left and right return springs (1) must be positioned in lateral guide of special tool 11 7 110 .

Fig 27: Positioning Return Spring

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Preload return spring with lever (1) on special tool 11 7 110 in direction of arrow.

Fig 28: Preloading Return Spring On Special Tool (11 7 110)

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Lock special tool 11 7 110 with catch on lever (1).

IMPORTANT: Screw fixing on return spring can only be released with special tool 11 7 110 secured.

Fig 29: Locking Special Tool (11 7 110) On Lever

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Release screw (1).

Fig 30: Releasing Screw

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WARNING: Risk of injury in event of incorrect use.
Lever (1) is under pre-tension.

IMPORTANT: Improper handling.
Risk of damage!

Secure lever (1)

Press back latching hook (2).

Return spring tension can now be released.

Fig 31: Pressing Latching Hook

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Release knurled screw (1) on special tool 11 7 110 in direction of arrow.

Fig 32: Releasing Knurled Screw On Special Tool (11 7 110)

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Release special tool 11 7 110 in direction of arrow from return spring (1).

Fig 33: Releasing Special Tool (11 7 110)

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Press torsion spring apart at positions (1).

Remove torsion spring towards top.

Fig 34: Removing Torsion Spring

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IMPORTANT: Uniform distribution must not be changed.
Place all components in clean and orderly condition in special tool 11 4 481.

All components must be reinstalled in the same positions in an engine which has already been in use.

Fig 35: Identifying Intermediate Lever Components On Special Tool

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Eccentric shaft with bearing
Bearing caps of eccentric shaft (set out in order)
Intake camshaft
Bearing caps of inlet camshaft (set out in order)
Intake valves with valve springs
Valve plates and valve cotters
Cam followers with HVCA elements (set out in order)
Torsion springs
Guide blocks (set out in order)
Intermediate levers (set out in order)

Release screws (1) on guide block (2).

Tightening torque 11 37 1AZ .

Place all guide blocks (2) in neat order in special tool 11 4 481.

Installation:

Mixing up the guide blocks (2) will cause the engine to suffer idle-speed fluctuations.

This will result in maladjustment of uniform distribution .

Fig 36: Identifying Screws On Guide Block

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Installation:

All contact surfaces (1) of guide block must be clean and free from oil and grease. If necessary, clean contact surfaces (1).

Fig 37: Identifying Contact Surface Of Guide Block

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Lift out intermediate levers (2).

Place all intermediate levers (2) in neat order in special tool 11 4 481.

Installation:

Mixing up the intermediate levers (2) will cause the engine to suffer idle-speed fluctuations.

Installation:

All contact surfaces (1) must be clean and free from oil and grease. If necessary, clean contact surfaces (1).

Fig 38: Identifying Contact Surface Of Guide Block

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All intermediate levers (1) are classified.

All intermediate levers (1) must be reinstalled in the same positions in an engine which has already been in use.

Fig 39: Locating Marking On Intermediate Levers

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IMPORTANT: Before installing intermediate levers (2), make sure cam followers are correctly positioned.
Risk of damage!

Install intermediate levers (2).

Fig 40: Identifying Contact Surface Of Guide Block And Intermediate Levers

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Fit guide block (2) cleanly into opening.

Tighten screws (1) hand-tight.

Check that intermediate levers are in correct installation position.

Release screws (1) by a 1/4 turn.

Fig 41: Identifying Guide Block And Screws

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Secure special tool 11 4 450 to screw fixing (1) of eccentric shaft.

Move eccentric lever (3) on special tool 11 4 450 in direction of arrow.

Guide block is now pretensioned.

Insert screws (2) of guide blocks.

Tightening torque 11 37 1AZ .

Installation:

At cylinder no. 3, the guide block can be pre-installed with one screw (internal) only.

Oil spray nozzle is fitted only after torsion spring has been installed.

Fig 42: Moving Eccentric Lever On Special Tool (11 4 450)

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Install torsion spring (2) on guide block.

Installation:

Insert torsion spring (2) in intermediate lever (1) (see arrow).

Check that cam follower (3) is in correct installation position.

Fig 43: Inserting Torsion Spring On Intermediate Lever

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Position special tool 11 7 110 on return spring.

Fig 44: Positioning Special Tool (11 7 110) On Return Spring

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Clamp return spring with knurled screw (1) in direction of arrow.

Fig 45: Compressing Return Spring With Knurled Screw

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Return spring (1) is positioned correctly when catches (see arrows) are surrounding return spring (1).

Fig 46: Positioning Return Spring

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WARNING: Risk of injury in event of incorrect use.

IMPORTANT: Improper handling.
Risk of damage!
Check return spring on intermediate lever to ensure correct installation position.

Press special tool 11 7 110 to stop in direction of arrow.

Fig 47: Pressing Special Tool (11 7 110)

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IMPORTANT: Pay attention to thread on cylinder head.
Risk of damage!

Tighten bolt (1).

Tightening torque 11 37 2AZ .

Fig 48: Tightening Bolt

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At cylinder no. 3, adjust oil spray nozzle (2) so that oil spray points precisely towards spline teeth (3).

Insert screw (1) with oil spray nozzle (2) (external).

Tightening torque 11 37 4AZ .

Fig 49: Identifying Oil Spray Nozzle With Spray

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Assemble engine.