Installing all intermediate levers

Checking the intermediate lever classification

NOTE: TECHNICAL INFORMATION
All intermediate levers are classified. Only one classification may be used per engine.
All intermediate levers must be reinstalled in the same positions in an engine which has already been in use.

Check the classification (arrow) of the intermediate lever.

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Checking installation position of roller cam followers

NOTE: TECHNICAL INFORMATION
The rocker arms may slip slightly when the camshaft is positioned. Make sure rocker arms are correctly positioned on the hydraulic valve clearance compensating elements and on valves.

Make sure the installation position (arrows) of the roller cam followers (1) is correct.

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Installing all intermediate levers

NOTE: TECHNICAL INFORMATION
When replacing one or more intermediate levers:
When removing the intermediate lever, it is imperative to note the part number of the intermediate lever.
A mixed installation of intermediate levers is only permitted in combination with the appropriate torsion spring.
For further information on possible combinations, see the applicable BMW parts catalogue.

Version with torsion spring with L-shaped contour and appropriate intermediate lever:
Use the torsion spring (1) with L-shaped contour only in connection with the appropriate intermediate lever (2).

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Version with torsion spring with S-shaped contour and appropriate intermediate lever:

Use the torsion spring (1) with S-shaped contour only in connection with the appropriate intermediate lever (2).

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NOTE: The description is for one component only. The procedure is identical for all further components.

Install the intermediate lever (1).

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Installing all gates

Have the special tool 2 359 089 ready.

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Clean contact surfaces (1) and (2) and remove the oil, grease and dirt.

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Position the gate (2) and hand-tighten the screw (1).
Make sure the intermediate lever (3) is in the correct installation position.

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Position the special tool 2 359 089 on the cylinder head.
Pre-tension the gate with the lever (3).
Abut the screw (1) in the area (2).
Make sure that the special tool 2 359 089 does not rotate during this process.

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Secure the gate with the lever (1) in the direction of the arrow.

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Make sure that the special tool 2 359 089 rests flat against the cylinder head (arrows).

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Press the special tool onto the cylinder head 2 359 089 in arrow direction and tighten the screw (1) simultaneously.

TIGHTENING TORQUE SPECIFICATIONS

Gate to bearing bracket
M7x35	23 Nm

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Check the conventional gauge (1) in the area (A) for the correct gap dimension.

TECHNICAL DATA SPECIFICATIONS

Gap dimension between gate and bearing bracket
Gap dimension A		0.03 mm

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Make sure the gate (1) lies correctly against the bearing bracket (2).
The gate (1) is correctly installed in the marked area.

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Make sure that the gate lies (1) correctly on the bearing bracket (2).

The gate (1) is not correctly installed in the marked area.

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Repeat the step for all the gates.

Check the position of the intake camshaft at cylinders 3 and 4

Check

Check the position of the intake camshaft at cylinders 3 and 4.

To remove the torsion springs on cylinders 3 and 4, the camshaft sensor wheel (1) of the intake camshaft must be positioned as shown.

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Result

» Camshaft sensor wheel (1) of the intake camshaft is not in the indicated position.

Measure

Turn the engine on the vibration damper with the special tool 0 493 380 (11 6 480) until camshaft sensor wheel (1) of the intake camshaft is positioned as shown.

Check the position of the intake camshaft at cylinders 3 and 4 (cylinder head removed)

Check

Check the position of the intake camshaft at cylinders 3 and 4.

To remove the torsion springs on cylinders 3 and 4, the camshaft sensor wheel (1) of the intake camshaft must be positioned as shown.

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Result

» Camshaft sensor wheel (1) of the intake camshaft is not in the indicated position.

Measure

Continue to crank the intake camshaft on the mounting flats.

Installing the torsion springs

CAUTION: Spring preload.
Injury hazard!

The use of the specified special tool (tool) is mandatory.
Carry out the described steps properly.

NOTE: TECHNICAL INFORMATION
Wear safety goggles.

NOTE: TECHNICAL INFORMATION
For disassembly and installation of the torsion spring, special tool 2 359 088 is used. Due to technical modifications in the torsion spring, special tool 5 A0B 120 is mounted on the existing special tool 2 359 088 .
Information on modification can be found in the additional information.

NOTE: TECHNICAL INFORMATION
Alternative to the new special tool 5 A24 F30 , the already known special tool SWZ: 2 359 088 can be used in modified form.
Information on modification can be found in the additional information.
The modified special tool is upward compatible.

NOTE: TECHNICAL INFORMATION
When replacing one or more torsion springs:
When removing the torsion spring, it is imperative to note the part number of the torsion spring.
A mixed installation of torsion springs is only permitted in combination with the appropriate intermediate lever.
For further information on possible combinations, see the applicable BMW parts catalogue.

Version with torsion spring with L-shaped contour and the suitable intermediate lever:
Use the torsion spring (1) with L-shaped contour only in connection with the suitable intermediate lever (2).

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Version with torsion spring with s-shaped contour and the suitable intermediate lever:

Use the torsion spring (1) with s-shaped contour only in connection with the suitable intermediate lever (2).

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Prepare the set of special tools 2 359 088 to remove the torsion spring with an s-shaped contour:

Number	Description
1	Clamping lever
2	Mount for clamping lever (torsion spring with s-shaped contour)

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Prepare the set of special tools 5 A24 F30 or alternatively modified special tool 2 359 088 to remove the torsion spring with an L-/s-shaped contour:

Number	Description
1	Clamping lever
2	Mount for clamping lever (torsion spring with L-/s-shaped contour)

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Version with torsion spring with s-shaped contour with the special tool 5 A24 F30 or the modified special tool 2 359 088 :
Bring the shaped element (1) in the direction of arrow on to the contact surface.

Hand-tighten the wing screw (2).

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Version with torsion spring with L-shaped contour with the special tool 5 A24 F30 or modified special tool 2 359 088 :

Bring the shaped element (1) in the direction of arrow on to the contact surface.

Hand-tighten the wing screw (2).

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Position the torsion spring (1) in the clamping lever (2).

The torsion spring (1) must be positioned in the marked area (3) of the clamping lever (2) correctly.

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Version with torsion spring with s-shaped contour with the special tool 2 359 088 :
Close the clamping lever (1) of the special tool 2 359 088 in the associated mount carefully until the retaining hook engages audibly.

While clamping, ensure that the torsion spring (2) lies correctly in the lateral guides (arrows) and mark of the clamping lever (1).

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Version with torsion spring with s-shaped contour with the special tool 5 A24 F30 or the modified special tool 2 359 088 :
Close the clamping lever (1) of the special tool 5 A24 F30 or the modified special tool 2 359 088 in the associated mount carefully until the retaining hook engages audibly.

While clamping, ensure that the torsion spring (2) lies correctly in the lateral guides (arrows) and mark of the clamping lever (1).

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Version with torsion spring with L-shaped contour with the special tool 5 A24 F30 or modified special tool 2 359 088 :
Close the clamping lever (1) of the special tool 5 A24 F30 or the modified special tool 2 359 088 in the associated mount carefully until the retaining hook engages audibly.
While clamping, ensure that the torsion spring (2) lies correctly in the lateral guides (arrows) and mark of the clamping lever (1).

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Take the clamping lever (2) with the tensioned torsion spring carefully in the direction of arrow from the mount (3).

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Insert the torsion spring (2) with the clamping lever (1) in the cylinder head (3).

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Version with torsion spring with s-shaped contour on the intermediate lever
Insert the torsion spring (2) into the intermediate levers (1).
Check all roller cam followers (3) for correct installation position.

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Lay the clamping lever (1) flat in the marked area (2).
Press the clamping lever (1) together until the retaining hook (3) unlocks audibly.
Carefully open the clamping lever (1) until the torsion spring is relaxed completely.
Feed out and remove the clamping lever (1).

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Bring the torsion spring (1) with a commercially available plastic hammer (3) and a commercially available plastic wedge (2) in the direction of arrow to its correct fit.

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Check the correct mounting orientation of the torsion spring (arrow).

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Follow-up work

Refer to INSTALLING CYLINDER HEAD COVER .
Refer to INSTALLING FRONT ENGINE ENCAPSULATION .
Refer to INSTALLING THE AUXILIARY COOLANT PUMP OF THE EXHAUST TURBOCHARGER .
Refer to INSTALLING ACOUSTIC COVER AT FRONT .
Refer to INSTALLING CHARGE AIR LINE .
Refer to INSTALLING CLEAN AIR PIPE .
Refer to INSTALLING INTAKE SILENCER HOUSING .
Refer to CONNECTING THE COOLANT LINE TO THE HIGH-TEMPERATURE COOLANT CIRCUIT .
Refer to CONNECTING THE COOLANT LINE TO THE LOW-TEMPERATURE COOLING SYSTEM .
Refer to INSTALLING BOTH COOLANT EXPANSION TANKS .
Refer to FILLING THE HIGH-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLER DEVICE .
Refer to FILLING THE LOW-TEMPERATURE COOLANT CIRCUIT WITH THE VACUUM FILLER DEVICE .
Refer to BLEEDING THE LOW-TEMPERATURE COOLING SYSTEM .
Refer to BLEEDING THE HIGH-TEMPERATURE COOLANT SYSTEM .
Refer to CHECKING THE HIGH-TEMPERATURE COOLING SYSTEM FOR WATERTIGHTNESS .
Refer to CHECKING LOW-TEMPERATURE COOLING SYSTEM FOR WATERTIGHTNESS .
Refer to PREPARING THE INJECTORS FOR INSTALLATION .
Refer to INSTALLING INJECTORS .
Refer to INSTALLING FUEL DELIVERY LINE .
Refer to INSTALLING THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE PUMP AND THE HIGH-PRESSURE RAIL .
Refer to INSTALLING BOTH ACTUATORS .
Refer to INSTALLING THE IGNITION COILS .
Refer to INSTALLING THE LOWER RIGHT ENGINE BULKHEAD .
Refer to INSTALLING CORROSION PROTECTION COVER .
Refer to INSTALLING ACOUSTIC COVER .
Refer to INSTALLING SOUND INSULATION AT THE CENTER OF THE BULKHEAD UPPER PART .
Refer to REMOVING/INSTALLING TRAILING LINK AT TENSION STRUT TOWER .
Refer to ATTACHING COWL PANEL COVER .
Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT ON THE LEFT .
Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT ON THE RIGHT .
Refer to INSTALLING BOTH WIPER ARMS .
Refer to CHECKING/ADJUSTING THE ANGLE OF ATTACK OF A WIPER ARM TO THE WINDSHIELD .
Refer to CONNECTING NEGATIVE BATTERY CABLE (ENGINE COMPARTMENT) .
Refer to CONNECTING THE NEGATIVE BATTERY CABLE .
Refer to ACTIVATING HIGH-VOLTAGE SYSTEM .
Refer to INSTALLING THE FLAP IN THE RIGHT LUGGAGE COMPARTMENT TRIM PANEL .
Refer to INSTALLING THE FRONT UNDERBODY PROTECTION .