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Home >> Mini >> 2010 >> Cooper S, 2D Hatchback, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 2910 (Engine - Repair - E91) >> Variable Valve Gear >> 11 37 010 Removing and installing/replacing intermediate levers (N52K) >> Necessary preliminary tasks

Necessary preliminary tasks

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

Fig 1: Moving Eccentric Shaft
G04751039Courtesy of BMW OF NORTH AMERICA, INC.
NOTE: Oil spray nozzle must be removed from 3rd cylinder (make a note of installation position of oil spray nozzle).
Fig 2: Identifying Oil Spray Nozzle With Spray
G04751247Courtesy of BMW OF NORTH AMERICA, INC.
NOTE: Oil spray nozzle must be removed from 3rd cylinder (make a note of installation position of oil spray nozzle).

Secure special tool 11 4 270 to guide block (2) using locking pliers (3).

IMPORTANT: Special tool 11 4 270 is only secured to guide block (2).
The position of the locking pliers (3) on the special tool 11 4 270 must not be altered. Risk of damage! 
Fig 3: Identifying Locking 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: Improper handling. Risk of damage! 

Secure both bearing pins (2) in torsion springs with knurled screw (1) of special tool 11 4 270 .

Press special tool 11 4 270 to stop in direction of arrow.

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

Release screw (2) of torsion spring.

Tightening torque 11 37 2AZ .

To avoid misalignment of screw (2) with torsion spring, it is necessary when releasing screw (2) to relieve the tension on the special tool 11 4 270 evenly.

IMPORTANT: Thread on cylinder head. Risk of damage! 
Fig 5: Releasing Screw Of Torsion Spring
G04751232Courtesy of BMW OF NORTH AMERICA, INC.

Release tension on torsion spring (1) with special tool 11 4 270 .

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

Installation: 

Replace torsion spring (1) if metal lug (2) is faulty.

Fig 6: Replacing Tension On Torsion Spring Using Special Tool (11 4 270)
G04751233Courtesy of BMW OF NORTH AMERICA, INC.

Press torsion spring apart at positions (1).

Remove torsion spring towards top.

Fig 7: Removing Torsion Spring
G04751234Courtesy of BMW OF NORTH AMERICA, INC.
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.

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

Release screws (1) on guide block (2).

Tightening torque 11 37 1AZ .

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

Installation: 

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

This will result in maladjustment of uniform distribution  .

Fig 9: Identifying Guide Block And Screws
G04751236Courtesy of BMW OF NORTH AMERICA, INC.

Installation: 

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

Fig 10: Identifying Guide Block Contact Surfaces
G04751237Courtesy of BMW OF NORTH AMERICA, INC.

Lift out intermediate levers (2).

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

Installation: 

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

Installation: 

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

Fig 11: Identifying Intermediate Levers
G04751238Courtesy of BMW OF NORTH AMERICA, INC.

All intermediate levers (1) are classified.

All intermediate levers (1) must be reinstalled in the same positions in an engine which has already been in use.

Fig 12: Locating Marking On Intermediate Lever
G04751239Courtesy of BMW OF NORTH AMERICA, INC.
IMPORTANT: Before installing intermediate levers (2), make sure cam followers are correctly positioned.
Risk of damage! 

Install intermediate levers (2).

Fig 13: Identifying Intermediate Levers
G04751238Courtesy of BMW OF NORTH AMERICA, INC.

Fit guide block (2) cleanly into opening.

Tighten screws (1) hand-tight.

Check that intermediate levers are in correct installation position.

Release  screws (1) by a 1/4 turn.

Fig 14: Identifying Guide Block And Screws
G04751236Courtesy of BMW OF NORTH AMERICA, INC.

Secure special tool 11 4 450 to screw fixing (1) of eccentric shaft.

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

Guide block is now pretensioned.

Insert screws (2) of guide blocks.

Tightening torque 11 37 1AZ .

Installation: 

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

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

Fig 15: Moving Eccentric Lever On Special Tool (11 4 450)
G04751242Courtesy of BMW OF NORTH AMERICA, INC.

Install torsion spring (2) on guide block.

Installation: 

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

Check that cam follower (3) is in correct installation position.

Fig 16: Inserting Torsion Spring On Intermediate Lever
G04751243Courtesy of BMW OF NORTH AMERICA, INC.

Secure special tool 11 4 270 to guide block (2) using locking pliers (3).

IMPORTANT: Special tool 11 4 270 is only secured to guide block (2).
The position of the locking pliers (3) on the special tool 11 4 270 must not be altered. Risk of damage! 
Fig 17: Securing Special Tool (11 4 270) To Guide Block Using Locking Pliers
G04751230Courtesy of BMW OF NORTH AMERICA, INC.
WARNING: Risk of injury in event of incorrect use.
IMPORTANT: Improper handling. Risk of damage! 

Secure both bearing pins (2) in torsion springs with knurled screw (1) of special tool 11 4 270 .

IMPORTANT: Check torsion spring on intermediate lever to ensure correct installation position.
Fig 18: Securing Bearing Pins Using Special Tool (11 4 270)
G04751231Courtesy of BMW OF NORTH AMERICA, INC.

Press special tool 11 4 270 to stop in direction of arrow.

Insert screw (2) of torsion spring.

Tightening torque 11 37 2AZ .

To avoid misalignment of screw (2) with torsion spring, it is necessary when inserting screw (2) to increase tension on special tool 11 4 270 evenly.

IMPORTANT: Thread on cylinder head. Risk of damage! 

Remove special tool 11 4 270 .

Fig 19: Inserting Screw Of Torsion Spring
G04751232Courtesy of BMW OF NORTH AMERICA, INC.

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

Insert screw (1) with oil spray nozzle (2) (external).

Tightening torque 11 37 4AZ .

Fig 20: Identifying Oil Spray Nozzle With Spray
G04751247Courtesy of BMW OF NORTH AMERICA, INC.

Assemble engine.

Version 2 

Size (1) 58 mm 

Fig 21: Identifying Guide Block Dimension
G06900894Courtesy of BMW OF NORTH AMERICA, INC.


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

Fig 1: Moving Eccentric Shaft
G04751039Courtesy of BMW OF NORTH AMERICA, INC.
NOTE: Oil spray nozzle must be removed from 3rd cylinder (make a note of installation position of oil spray nozzle).
Fig 2: Identifying Oil Spray Nozzle With Spray
G04751247Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 3: Positioning Special Tool (11 7 110) On Return Spring
G06900918Courtesy of BMW OF NORTH AMERICA, INC.
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 guide block.

Fig 4: Turning Knurled Screw
G06900919Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 5: Identifying Special Tool (11 7 110)
G06900920Courtesy of BMW OF NORTH AMERICA, INC.
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 Spring
G06900921Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 7: Preloading Return Spring On Special Tool (11 7 110)
G06900922Courtesy of BMW OF NORTH AMERICA, INC.

Lock special tool 11 7 110 with catch on lever (1).

IMPORTANT: Screw fixing on return spring can only be released with special tool 11 7 110 secured.
Fig 8: Locking Special Tool (11 7 110) On Lever
G06900923Courtesy of BMW OF NORTH AMERICA, INC.

Release screw (1).

Fig 9: Releasing Screw
G06900924Courtesy of BMW OF NORTH AMERICA, INC.
WARNING: Risk of injury in event of incorrect use.
Lever (1) is under pre-tension.
IMPORTANT: Improper handling.
Risk of damage! 

Secure lever (1)

Press back latching hook (2).

Return spring tension can now be released.

Fig 10: Pressing Latching Hook
G06900925Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 11: Releasing Knurled Screw On Special Tool (11 7 110)
G06900926Courtesy of BMW OF NORTH AMERICA, INC.

Release special tool 11 7 110 in direction of arrow from return spring (1).

Fig 12: Releasing Special Tool (11 7 110)
G06900927Courtesy of BMW OF NORTH AMERICA, INC.

Press torsion spring apart at positions (1).

Remove torsion spring towards top.

Fig 13: Removing Torsion Spring
G04751234Courtesy of BMW OF NORTH AMERICA, INC.
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.

Fig 14: Identifying Intermediate Lever Components On Special Tool
G04751235Courtesy of BMW OF NORTH AMERICA, INC.
  1. Eccentric shaft with bearing
  2. Bearing caps of eccentric shaft (set out in order)
  3. Intake camshaft
  4. Bearing caps of inlet camshaft (set out in order)
  5. Intake valves with valve springs
  6. Valve plates and valve cotters
  7. Cam followers with HVCA elements (set out in order)
  8. Torsion springs
  9. Guide blocks (set out in order)
  10. Intermediate levers (set out in order)

Release screws (1) on guide block (2).

Tightening torque 11 37 1AZ .

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

Installation: 

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

This will result in maladjustment of uniform distribution  .

Fig 15: Identifying Screws On Guide Block
G06900930Courtesy of BMW OF NORTH AMERICA, INC.

Installation: 

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

Fig 16: Identifying Contact Surface Of Guide Block
G04751237Courtesy of BMW OF NORTH AMERICA, INC.

Lift out intermediate levers (2).

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

Installation: 

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

Installation: 

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

Fig 17: Identifying Contact Surface Of Guide Block
G04751238Courtesy of BMW OF NORTH AMERICA, INC.

All intermediate levers (1) are classified.

All intermediate levers (1) must be reinstalled in the same positions in an engine which has already been in use.

Fig 18: Locating Marking On Intermediate Levers
G04751239Courtesy of BMW OF NORTH AMERICA, INC.
IMPORTANT: Before installing intermediate levers (2), make sure cam followers are correctly positioned.
Risk of damage! 

Install intermediate levers (2).

Fig 19: Identifying Contact Surface Of Guide Block And Intermediate Levers
G04751238Courtesy of BMW OF NORTH AMERICA, INC.

Fit guide block (2) cleanly into opening.

Tighten screws (1) hand-tight.

Check that intermediate levers are in correct installation position.

Release  screws (1) by a 1/4 turn.

Fig 20: Identifying Guide Block And Screws
G04751236Courtesy of BMW OF NORTH AMERICA, INC.

Secure special tool 11 4 450 to screw fixing (1) of eccentric shaft.

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

Guide block is now pretensioned.

Insert screws (2) of guide blocks.

Tightening torque 11 37 1AZ .

Installation: 

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

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

Fig 21: Moving Eccentric Lever On Special Tool (11 4 450)
G04751242Courtesy of BMW OF NORTH AMERICA, INC.

Install torsion spring (2) on guide block.

Installation: 

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

Check that cam follower (3) is in correct installation position.

Fig 22: Inserting Torsion Spring On Intermediate Lever
G04751243Courtesy of BMW OF NORTH AMERICA, INC.

Position special tool 11 7 110 on return spring.

Fig 23: Positioning Special Tool (11 7 110) On Return Spring
G06900927Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 24: Compressing Return Spring With Knurled Screw
G06900923Courtesy of BMW OF NORTH AMERICA, INC.

Return spring (1) is positioned correctly when catches (see arrows) are surrounding return spring (1).

Fig 25: Positioning Return Spring
G06900924Courtesy of BMW OF NORTH AMERICA, INC.
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 26: Pressing Special Tool (11 7 110)
G06900925Courtesy of BMW OF NORTH AMERICA, INC.
IMPORTANT: Pay attention to thread on cylinder head.
Risk of damage! 

Tighten bolt (1).

Tightening torque 11 37 2AZ .

Fig 27: Tightening Bolt
G06900924Courtesy of BMW OF NORTH AMERICA, INC.

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

Insert screw (1) with oil spray nozzle (2) (external).

Tightening torque 11 37 4AZ .

Fig 28: Identifying Oil Spray Nozzle With Spray
G04751247Courtesy of BMW OF NORTH AMERICA, INC.

Assemble engine.

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