11 37 010 Removing and installing/replacing intermediate levers (N20)

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Special tools required:

WARNING: Risk of injury in event of incorrect use.

IMPORTANT: Improper handling. Risk of damage!

Necessary preliminary tasks:

Remove ALL IGNITION COILS AND INJECTOR SHAFTS .
Remove stop screws for ECCENTRIC SHAFT .

IMPORTANT: Secure eccentric shaft (1) with open-end spanner (3) (risk of return stroke).

Slowly adjust eccentric shaft (1) to minimum lift via servomotor using 4-mm hexagon socket wrench (2) and open-end spanner (3).

Fig 1: Securing Eccentric Shaft And Adjusting Via Servomotor Using 4mm Hexagon Socket Wrench

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Release bolt (1) on the oil spray nozzle.

Tightening torque: 11 37 4AZ .

Unclip oil spray nozzle (2) from the bracket on the actuator drive (3) in direction of arrow.

Fig 2: Identifying Oil Spray Nozzle, Bolt, And Bracket

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Remove minimum stroke stop (1).

Tightening torque: 11 37 5AZ .

Fig 3: Identifying Intermediate Lever Stop

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

Fig 4: 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 gate.

Fig 5: Turning Knurled Screw

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

Fig 6: Identifying Preloaded Return Spring

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Risk of damage!

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

Fig 7: Positioning Return Springs In Lateral Guide Of Special Tool (11 7 110)

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

Fig 8: 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 connection on throttle return spring can only be released with secured special tool 11 7 110 .

Fig 9: Locking Special Tool (11 7 110) With Catch On Lever

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Release screw (1).

Fig 10: Identifying Screw

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WARNING: Risk of injury in event of incorrect use.
Lever (1) is preloaded.

IMPORTANT: Improper handling. Risk of damage!

Secure lever (1).

Press back latching hook (2).

Return spring tension can now be released.

Fig 11: Identifying Latching Hook And Lever

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

Fig 12: 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 13: Releasing Special Tool (11 7 110) From Return Spring

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Press return spring (1) apart.

Remove return spring (1) upward.

Fig 14: Removing Return Spring

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

In the case of an engine which has already been in use, all components must be reinstalled in the same positions.

Fig 15: Identifying Removed Engine Components Properly Arranged On Tray (11 4 481)

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Eccentric shaft with bearing
Bearing caps of eccentric shaft (set out in order)
Intake camshaft
Bearing caps of intake camshaft (set out in order)
Intake valves with valve springs
Valve heads and valve keys
Rocker arm with hydraulic valve clearance compensating element (set out in order).
Return springs.
Gates (set out in order)
Intermediate levers (set out in order)

Release screws (1) on gate (2).

Tightening torque 11 37 1AZ .

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

Installation note:

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

Fig 16: Identifying Screws On Gate

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Installation note:

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

Fig 17: Identifying Contact Surfaces Of Gates

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Lift out intermediate levers (1).

Place all intermediate levers (1) in neat order in special tool 11 4 481 .

Installation note:

Mixing up the intermediate levers (1) will cause the engine to suffer idle-speed fluctuations.

Installation note:

All contact surfaces must be clean and free of oil and grease. If necessary, clean contact surfaces.

Fig 18: Identifying Intermediate Lever

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All intermediate levers are classified.

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

Intermediate levers are classified from 1 to 5.

Fig 19: Locating Classification Number On Intermediate Lever

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IMPORTANT: Before installing intermediate levers (1), make sure rocker arms are correctly positioned.
Risk of damage!

Fig 20: Identifying Roller Cam Follower

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Install intermediate levers (1).

Fig 21: Identifying Intermediate Lever

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Fit gate (2) cleanly into recess.

Tighten screws (1) hand-tight.

Check that intermediate levers are in correct installation position.

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

Fig 22: Identifying Gate And Screws

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Secure special tool 11 4 450 on screw connection of eccentric shaft and set adjusting screw on special tool 11 4 450 , if necessary.

Turn eccentric lever on special tool 11 4 450 in direction of arrow.

Gate is now preloaded.

Fasten screws (1) of gates.

Tightening torque 11 37 1AZ .

Installation note:

Fig 23: Turning Eccentric Lever

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

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

Graphic N55.

Press return spring (1) apart.

Install return spring (1).

Graphic N55.

Fig 24: Removing Return Spring

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Install return spring (2) on gate.

Installation note:

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

Check that rocker arm (3) is in correct installation position.

Fig 25: Identifying Throttle Return Spring, Intermediate Lever, And Roller Cam Follower

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Position special tool 11 7 110 on return spring.

Fig 26: Releasing Special Tool (11 7 110) From Return Spring

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

Fig 27: Clamping Throttle Return Spring With Knurled Screw

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Return spring (1) is positioned correctly when latching hooks surround return spring (1).

Fig 28: 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 29: Pressing Special Tool (11 7 110)

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IMPORTANT: Observe thread on cylinder head.
Risk of damage!

Tighten bolt (1).

Tightening torque 11 37 2AZ .

Fig 30: Identifying Screw

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Retract oil spray nozzle (2) on actuator drive (3).

Engage bolt (1) and release back to 90°.

For exact positioning of the oil spray nozzle (2) audibly clip it in at the top.

Tightening torque 11 37 4AZ .

Fig 31: Identifying Oil Spray Nozzle, Bolt, And Bracket

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Assemble engine.