11 37 010 Removing and Installing/Replacing Intermediate Levers (N55)

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Special Tools Required:

WARNING: Risk of Injury In Event of Incorrect Use.

IMPORTANT: Improper Handling. Risk of Damage!

IMPORTANT: 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 .
Joining Torque and Angle of Rotation Must Be Observed Without Fail (Risk of Damage) .

Necessary Preliminary Tasks:

Remove CYLINDER HEAD COVER .
Remove Wiper Console (E70/E71).
Remove ALL IGNITION COILS AND INJECTOR SHAFTS .

Slowly Adjust Eccentric Shaft In Direction of Arrow To Minimum Stroke Via The Servomotor with A 4-Mm Hexagon Socket Wrench (2) and An Open-End Spanner (1).

IMPORTANT: Secure Eccentric Shaft with Open-End Spanner (1) (Risk of Return Stroke).

Fig 1: Adjusting Eccentric Shaft

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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: Removing Oil Spray Nozzle From Actuator Drive Bracket

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Position Special Tool 11 7 110 On Return Spring (1) (See Arrows In Illustration).

Fig 3: 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 4: Placing Special Tool (11 7 110) Flat On Cylinder Head and Turning Knurled Screw To Secure Return Spring In Gate

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Return Spring Is Correctly Preloaded When Both Clamping Levers Are Parallel To Guide Block.

Fig 5: Identifying Correct Pre-Loading of Return Spring

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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 6: Positioning Return Springs In Lateral Guide of Special Tool

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Preload Return Spring with Lever (1) On Special Tool 11 7 110 In Direction of Arrow.

Fig 7: Pre-Loading Return Spring

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Lock Special Tool 11 7 110 with Latching Hook On Lever (1).

IMPORTANT: Screw Connection On Return Spring Can First Be Released with Secured Special Tool 11 7 110 .

Fig 8: Locking Special Tool (11 7 110) On Lever

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Release Screw (1).

Fig 9: 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 10: Identifying Latching Hook and Lever

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Release Knurled Screw (1) On Special Tool 11 7 110 In Direction of Arrow.

Fig 11: Releasing Special Tool Knurled Screw

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Release Special Tool 11 7 110 From Return Spring (1) In Direction of Arrow.

Fig 12: Releasing Special Tool From Return Spring

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Press Return Spring (1) Apart.

Remove Return Spring (1) Upward.

Fig 13: Removing Return 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.

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 Arms with HVCA Elements (Set Out In Order)
Return Springs.
Gates (Set Out In Order)
Intermediate Levers (Set Out In Order)

Fig 14: Identifying Removed Components Arranged On Tray 11 4 481

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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.

This Will Result In Maladjustment of Uniform Distribution .

Fig 15: Identifying Gate and Screws

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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 16: Identifying Contact Surfaces of Gate

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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 17: 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 18: Locating Classification Mark On Intermediate Lever

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IMPORTANT: Before Installing Intermediate Levers (1), Make Sure Rocker Arms Are Correctly Positioned.
Risk of Damage!

Fig 19: Identifying Roller Cam Follower

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Install Intermediate Levers (1).

Fig 20: 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 21: Identifying Gate and Screws

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Secure Special Tool 11 4 450 On Screw Connection (1) 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.

Insert Screws (1) of Gates.

Tightening torque 11 37 1AZ .

Installation Note:

At Cylinder No. 3, The Gate Can Be Pre-Installed with One Screw (Internal) Only.

Fig 22: Securing Special Tool and Pre-Loading Gate By Turning Lever

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Oil Spray Nozzle Is Fitted Only After Return Spring Has Been Installed.

Press Return Spring (1) Apart.

Install Return Spring (1).

Fig 23: 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 In Illustration).

Check That Rocker Arm (3) Is In Correct Installation Position.

Fig 24: Identifying Throttle Return Spring, Intermediate Lever, and Roller Cam Follower

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Position Special Tool 11 7 110 On Return Spring.

Fig 25: Releasing Special Tool From Return Spring

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Clamp Return Spring with Knurled Screw (1) In Direction of Arrow.

Fig 26: Clamping Return Spring Knurled Screw

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Return Spring (1) Is Positioned Correctly When Latching Hooks Surround Return Spring (1).

Fig 27: Identifying Correct Positioning of 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 28: 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 29: Identifying Bolt

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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 30: Removing Oil Spray Nozzle From Actuator Drive Bracket

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Assemble Engine.