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1137010 Removing and installing/replacing intermediate lever (N51)

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2011 BMW 328xi, 2011 BMW 328i, 2010 BMW 328xi, 2010 BMW 328i, and 2009 BMW 328xi. However, it is still accessible from the selected car via links, so may be relevant.
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). 

Necessary preliminary tasks: 

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

Fig 1: Turning Eccentric Shaft
G04751039Courtesy of BMW OF NORTH AMERICA, INC.

Secure special tool 11 4 270 DEVICE with gripping pliers (3) to guide block (2).

IMPORTANT: Special tool 11 4 270 DEVICE is only secured to guide block.
Adjusting the gripping pliers (3) is not permitted (risk of damage) on special tool 11 4 270 DEVICE .
NOTE: The oil nozzle must be removed beforehand from cylinder no. 3.
Fig 2: Identifying Gripping Pliers, Guide Block And Special Tool (11 4 270)
G04751230Courtesy of BMW OF NORTH AMERICA, INC.
WARNING: Risk of injury in event of incorrect use.
IMPORTANT: Incorrect handling - risk of damage! 

Secure both bearing pins (2) in return spring with knurled screw (1) on special tool 11 4 270 DEVICE .

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

Fig 3: Pressing Special Tool (11 4 270)
G04751231Courtesy of BMW OF NORTH AMERICA, INC.

Release steel screw (2).

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

IMPORTANT: Risk of damage to cylinder head thread.

Tightening torque: 11 37 2AZ .

Fig 4: Releasing Steel Screw
G04751232Courtesy of BMW OF NORTH AMERICA, INC.

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

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

Installation: 

Replace metal lug if tab washer is defective.

Fig 5: Removing Metal Lugs
G04751233Courtesy of BMW OF NORTH AMERICA, INC.

Press return spring apart at position (1) and remove towards top.

Fig 6: Pressing Torsion Spring
G04751234Courtesy of BMW OF NORTH AMERICA, INC.
IMPORTANT: Uniform distribution must not  be changed.
All components must be set down in a clean and orderly  fashion.

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

  1. Eccentric shaft with bearing
  2. Bearing caps of eccentric shaft set out in order.
  3. Inlet camshaft
  4. Bearing caps of inlet camshaft set out in order.
  5. Intake valves with valve springs
  6. Valve plates and valve cotters
  7. Roller cam followers with HVC element set out in order.
    Fig 7: Identifying Components And Special Tool (11 4 481)
    G04751235Courtesy of BMW OF NORTH AMERICA, INC.
  8. Return springs.
  9. Guide blocks set out in order.
  10. Intermediate levers set out in order.

Release screws (1).

Tightening torque: 11 37 1AZ .

Set down guide blocks (2) in special tool 11 4 481 in neat order.

Installation: 

Mixing up the guide blocks may cause the engine to demonstrate idle fluctuations.

This will result in maladjustment of uniform distribution  .

Fig 8: Identifying Screws And Guide Block
G04751236Courtesy of BMW OF NORTH AMERICA, INC.

Installation: 

Contact surfaces (1) must be clean and oil-free.

Clean if necessary.

Fig 9: Identifying Contact Surface
G04751237Courtesy of BMW OF NORTH AMERICA, INC.

Lift out intermediate levers (2).

Intermediate levers (2) set out in special tool 11 4 481 in order.

Installation: 

Mixing up the intermediate levers may cause the engine to demonstrate RPM fluctuations.

Installation: 

Contact surfaces (1) must be clean and oil-free.

Clean if necessary.

Fig 10: Identifying Contact Surface And Intermediate Levers
G04751238Courtesy of BMW OF NORTH AMERICA, INC.

All intermediate levers (1) are classified.

Reinstall intermediate levers which have already been used in the same positions.

Fig 11: Locating Marking On Intermediate Levers
G04751239Courtesy of BMW OF NORTH AMERICA, INC.

Installation: 

Before reinstalling the intermediate levers, make sure the roller cam followers are correctly positioned (risk of damage). 

Install intermediate levers (2).

Fig 12: Identifying Contact Surfaces And Intermediate Levers
G04751238Courtesy of BMW OF NORTH AMERICA, INC.

Fit guide block (2) cleanly into opening.

Tighten screws (1) hand-tight.

Check both intermediate levers again to ensure correct installation position.

Release  bolts (1) again by a 1/4 turn.

Fig 13: Identifying Guide Block With Bolts
G04751236Courtesy of BMW OF NORTH AMERICA, INC.

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

Turn eccentric lever (3) on special tool 11 4 450 DEVICE in direction of arrow.

Guide block is now tensioned.

Secure screws (2).

Tightening torque: 11 37 1AZ .

Installation: 

At cylinder no. 3, the guide block can be preinstalled with one bolt (2) only.

Fit oil pump only after retaining spring has been fitted.

Fig 14: Turning Eccentric Lever
G04751242Courtesy of BMW OF NORTH AMERICA, INC.

Fit return spring on guide block.

Installation: 

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

Check roller cam follow (3) again to ensure correct installation position.

Fig 15: Inserting Torsion Spring In Intermediate Lever
G04751243Courtesy of BMW OF NORTH AMERICA, INC.

Secure special tool 11 4 270 DEVICE with gripping pliers (3) to guide block (1).

IMPORTANT: Special tool 11 4 270 DEVICE is only secured to guide block.
Adjusting the gripping pliers (3) is not permitted (risk of damage) on special tool 11 4 270 DEVICE .
Fig 16: Identifying Gripping Pliers, Guide Block And Special Tool (11 4 270)
G04751230Courtesy of BMW OF NORTH AMERICA, INC.
WARNING: Risk of injury in event of incorrect use.
IMPORTANT: Incorrect handling risk of damage. 

Secure both bearing pins (2) in return spring with knurled screw (1) on special tool 11 4 270 DEVICE .

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

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

Fig 17: Pressing Special Tool (11 4 270)
G04751231Courtesy of BMW OF NORTH AMERICA, INC.

Insert steel screw (2).

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

IMPORTANT: Risk of damage to cylinder head thread.

Tightening torque: 11 37 2AZ .

Remove special tool 11 4 270 DEVICE .

Fig 18: Inserting Steel Screw
G04751232Courtesy of BMW OF NORTH AMERICA, INC.

At cylinder no. 3, adjust oil nozzle (2) so that oil spray (3) points precisely towards spline teeth.

Fig 19: Identifying Oil Spray Nozzle With Spray
G04751247Courtesy of BMW OF NORTH AMERICA, INC.

Assemble engine.

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