Removing all intermediate levers
Prerequisite
- Intake plenum removed.
The high-voltage system operates on the basis of hazardous, electrical voltage and high currents. Mortal hazard through electric shock!
- All work on the high-voltage system may only be carried out by specially trained and technically experienced personnel.
- For additional information see:
- For additional information see:
Preliminary work
- Refer to REMOVING THE FLAP IN THE RIGHT-HAND LUGGAGE COMPARTMENT TRIM PANEL .
- Refer to DE-ENERGIZING THE HIGH-VOLTAGE SYSTEM .
- Refer to CHECKING THAT NO VOLTAGE IS APPLIED .
- Refer to DISCONNECTING THE NEGATIVE BATTERY CABLE .
- Refer to DISCONNECTING THE NEGATIVE BATTERY CABLE OF THE VEHICLE BATTERY .
- Refer to REMOVING THE RIGHT COVER IN THE ENGINE COMPARTMENT .
- Refer to REMOVING THE COVER IN THE LEFT ENGINE COMPARTMENT .
- Refer to REMOVING BOTH WIPER ARMS
- Refer to REMOVING COWL PANEL COVER .
- Refer to REMOVING TRAILING LINK AT TENSION STRUT TOWER .
- Refer to REMOVING THE SOUND INSULATION ON THE BULKHEAD UPPER PART AT THE CENTER .
- Refer to REMOVING THE LOWER RIGHT ENGINE BULKHEAD .
- Refer to REMOVING THE ACOUSTIC COVER .
- Refer to REMOVING CORROSION PROTECTION COVER .
- Refer to REMOVING BOTH ACTUATORS .
- Refer to REMOVING IGNITION COILS .
- Refer to REMOVING THE HIGH PRESSURE LINE BETWEEN THE HIGH PRESSURE PUMP AND THE RAIL .
- Refer to REMOVING FUEL DELIVERY LINE .
- Refer to REMOVING THE INJECTORS .
- Refer to REMOVING THE FRONT UNDERBODY PROTECTION .
- Refer to DRAINING THE COOLANT FROM THE LOW-TEMPERATURE COOLING SYSTEM .
- Refer to DRAINING THE COOLANT FROM THE HIGH-TEMPERATURE COOLING SYSTEM .
- Refer to REMOVING BOTH COOLANT EXPANSION TANKS .
- Refer to REMOVING INTAKE SILENCER HOUSING .
- Refer to REMOVING CLEAN AIR PIPE .
- Refer to REMOVING CHARGE AIR LINE .
- Refer to REMOVING ACOUSTIC COVER AT FRONT .
- Refer to REMOVING THE AUXILIARY COOLANT PUMP OF THE EXHAUST TURBOCHARGER .
- Refer to REMOVING FRONT ENGINE ENCAPSULATION .
- Refer to REMOVING THE CYLINDER HEAD COVER .
Checking the position of the intake camshaft
Check
- Check position of the intake camshaft on the respective cylinders.
Result
» Cam (1) of the intake camshaft runs on the intermediate lever.
Measure
- Continue to turn the engine at the vibration damper with the special tool 0 493 380 (11 6 480) in the direction of engine rotation.
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.
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.
Remove the torsion springs
Torsion spring
(L-shaped contour)
Injury hazard!
- The use of the specified special tool (tool) is mandatory.
- Carry out the described steps properly.
Wear safety goggles.
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.
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.
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.
- Prepare set of special tools 2 359 088
for removing the torsion spring with an S-shaped contour:
Number Description 1 Clamping lever 2 Mount for clamping lever (for torsion spring with an S-shaped contour) - Prepare set of special tools 5 A24 F30 or alternatively modified special tool 2 359 088 for removing the torsion spring with an L/S-shaped contour:
| Number | Description |
|---|---|
| 1 | Clamping lever |
| 2 | Mount for clamping lever (for torsion spring with an L/S-shaped contour) |
- Version with torsion spring with an S-shaped contour using special tool 5 A24 F30
or modified special tool 2 359 088
:
Bring the shaped element (1) to the contact surface in the direction of arrow.
Hand-tighten the wing screw (2).
- Version with torsion spring with an L-shaped contour using special tool 5 A24 F30 or modified special tool 2 359 088 :
Bring the shaped element (1) to the contact surface in the direction of arrow.
Hand-tighten the wing screw (2).
- Open the clamping lever (1) and position on the torsion spring (2).
- Ensure that the clamping lever (1) lies flat in the area (2) on the cylinder head.
- Close the clamping lever (1)
carefully until the retaining hook (3)
engages audibly.
Check
- Check whether the clamping lever (1) is positioned correctly in the marked areas on the torsion spring.
Result
» The clamping lever (1) is not positioned correctly on the torsion spring.
Measure
- Carefully release the clamping lever (1) and repeat the process.
- Clamp the mount (1) in the vice (2).
- Position the clamping lever (3) with the preloaded torsion spring (5) in the mount (1) in the direction of arrow.
The retaining hook (4) of the clamping lever (3) is used for releasing the clamping lever (3).
The torsion spring (5) is thus released.
- Version with torsion spring with an S-shaped contour and the special tool 2 359 088
.
Carefully unlock the clamping lever (1) of the special tool 2 359 088 in the corresponding mount.
Make sure that the torsion spring (2) lies correctly in the lateral guides (arrows) and mark of the clamping lever (1) during releasing.
Place the torsion spring (2) neatly in the special tool 0 495 105 (11 4 480) .
- Version with torsion spring with an S-shaped contour and special tool 5 A24 F30
or modified special tool 2 359 088
:
Carefully unlock the clamping lever (1) of special tool 5 A24 F30 or alternatively of modified special tool 2 359 088 in the corresponding mount.
Make sure that the torsion spring (2) lies correctly in the lateral guides (arrows) and mark of the clamping lever (1) during releasing.
Place the torsion spring (2) neatly in the special tool 0 495 105 (11 4 480) .
- Version with torsion spring with an L-shaped contour and special tool 5 A24 F30 or modified special tool 2 359 088 :
Carefully unlock the clamping lever (1) of the special tool 5 A24 F30 or of the modified special tool 2 359 088 in the corresponding mount.
Make sure that the torsion spring (2) lies correctly in the lateral guides (arrows) and mark of the clamping lever (1) during releasing.
Place the torsion spring (2) neatly in the special tool 0 495 105 (11 4 480) .
- Repeat the operations for the remaining torsion springs.
Removing all gates
- Loosen screw (1).
- Remove the gate (2) and place it arranged in order into 0 495 105 (11 4 480).
- Repeat the step for all the gates.
Removing all intermediate levers
Intermediate lever
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.
- Remove the intermediate lever (1) and arrange it in the special tool 0 495 105 (11 4 480) in order.