11 37 010 Removing and installing/replacing intermediate levers (N52K)

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2010 BMW 528xi, 2010 BMW 528i, 2009 BMW 528xi, 2009 BMW 528i, and 2008 BMW 528xi. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

IMPORTANT: Aluminium-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

Fig 1: Identifying Guide Block Dimension

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Necessary preliminary tasks:

Remove cylinder head cover

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

Fig 2: Identifying Eccentric Shaft And Lift

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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 3: Identifying Screw With Oil Spray Nozzle

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Secure special tool 114270 with gripping pliers (3) to guide block (2).

IMPORTANT: Special tool 11 4 270 is only secured to guide block (2).
Adjusting the gripping pliers (3) on special tool 11 4 270 is not permitted. Risk of damage!

Fig 4: Securing Special Tool 114270 With Gripping Pliers To Guide Block

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WARNING: Risk of injury in event of incorrect use.

IMPORTANT: Improper handling. Risk of damage!

Secure both bearing pins (2) in torsion springs with knurled screw (1) of special tool 11 4 270 .

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

Fig 5: Identifying Bearing Pins And Knurled Screw

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Release screw (2) of torsion spring.

Tightening torque 11 37 2AZ .

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

IMPORTANT: Thread on cylinder head. Risk of damage!

Fig 6: Identifying Special Tool 11 4 270

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

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

Installation:

Replace torsion spring (1) if metal lug (2) is faulty.

Fig 7: Identifying Special Tool 11 4 270

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Press torsion spring apart at positions (1).

Remove torsion spring towards top.

Fig 8: Pressing Torsion Spring

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

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

Eccentric shaft with bearing
Bearing caps of eccentric shaft (set out in order)
Inlet camshaft
Bearing caps of inlet camshaft (set out in order)
Inlet 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)

Fig 9: Identifying Special Tool 11 4 481

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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 10: Identifying Guide Blocks And Screws

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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 11: Identifying Contact Surfaces 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 12: Identifying Contact Surfaces And Intermediate Levers

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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 13: Identifying 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 14: Identifying Contact Surfaces 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 15: Identifying Screws And Guide Block

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

Turn 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 16: Identifying Eccentric Lever, Screws And Special Tool

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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 17: Identifying Torsion Spring, Intermediate Lever And Cam Follower

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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 (2).
Adjusting the gripping pliers (3) on special tool 11 4 270 is not permitted. Risk of damage!

Fig 18: 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: Improper handling. Risk of damage!

Secure both bearing pins (2) in torsion springs with knurled screw (1) of special tool 11 4 270 .

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

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

Fig 19: Identifying Bearing Pins And Knurled Screw

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Insert screw (2) of torsion spring.

Tightening torque 11 37 2AZ .

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

IMPORTANT: Thread on cylinder head. Risk of damage!

Remove special tool 11 4 270 .

Fig 20: Identifying Special Tool 11 4 270

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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 21: Identifying Screw, Oil Spray Nozzle And Spline Teeth

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Assemble engine.

Version 2

Size (1) 58 mm

Fig 22: Identifying Guide Block Dimension

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Necessary preliminary tasks:

Remove CYLINDER HEAD COVER
For E81, E82, E87, E88, E90, E91, E92, E93: Remove cowl panel cover.

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

Fig 23: Turning Eccentric Shaft To Minimum Lift

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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 24: Identifying Oil Spray Nozzle, Spline Teeth And Screw

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

Fig 25: Locating 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 26: Turning Knurled Screw

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

Fig 27: Identifying Guide Block With 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 28: Identifying Return Springs In Lateral Special Tool 11 7 110 Lateral Guide

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

Fig 29: Identifying Return Spring With Lever And 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 30: Locking Special Tool 11 7 110 With Catch On Lever

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Release screw (1).

Fig 31: Identifying Special Tool 11 7 110 And Screws

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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!

Fig 32: Identifying Latching Hook, Lever With Special Tool 11 7 110

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Secure lever (1)

Press back latching hook (2).

Return spring tension can now be released.

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

Fig 33: 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 34: Releasing Special Tool 11 7 110

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Press torsion spring apart at positions (1).

Remove torsion spring towards top.

Fig 35: Pressing Torsion Spring Apart

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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.

Fig 36: Identifying Components With Special Tool (11 4 481)

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

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 37: Identifying Guide Block With Mounting Screws

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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 38: Identifying Guide Block Contact Surface

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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 39: Identifying Contact Surfaces And Intermediate Levers

Courtesy of BMW OF NORTH AMERICA, INC.

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 40: Identifying 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 41: Identifying Contact Surfaces 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 42: Identifying Screws And Guide Block

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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 .

Fig 43: Turning Eccentric Lever

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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.

Install torsion spring (2) on guide block.

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

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

Fig 44: Inserting Torsion Spring In Intermediate Lever

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Position special tool 11 7 110 on return spring.

Fig 45: 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 46: Clamping 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 47: Identifying Return Spring With Screws And Special Tool 11 7 110

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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 48: Identifying Latching Hook, Lever With 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 49: Identifying Return Spring With Screws And Special Tool 11 7 110

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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 50: Identifying Oil Spray Nozzle, Spline Teeth And Screw

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Assemble engine.