11 37 012 Removing and installing/replacing left intermediate lever (N62 to 9/03)

WARNING: This page is about a different car, the 2005 BMW 545i and 2004 BMW 545i. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

For Special Tool identification, see ENGINE - SPECIAL TOOLS - 5-SERIES (E60) .

Special Tools Required:

11 9 470
11 9 472
11 9 473
11 9 474
11 9 475
11 9 480
11 9 490

(cylinder bank 5 to 8)

Removal:

Removal of intermediate levers is described separately from installation.

Remove servomotor for left eccentric shaft. Refer to 11 37 022 REMOVING AND INSTALLING/REPLACING SERVOMOTOR FOR LEFT ECCENTRIC SHAFT (N62/N62TU) .

Remove ignition coils on cylinder bank 5 to 8.

Remove left cylinder head cover. Refer to 11 12 005 REMOVING AND INSTALLING/SEALING LEFT CYLINDER HEAD COVER (N62/N62TU) .

Remove spark plugs on cylinder bank 5 to 8.

Remove inlet and exhaust adjustment unit on left side. Refer to 11 36 047 REMOVING AND INSTALLING/REPLACING INLET AND EXHAUST ADJUSTMENT UNITS ON LEFT SIDE (N62/N62TU) .

IMPORTANT: The inlet camshaft must first be rotated so that when the bearing bracket is removed the intermediate levers do not slip out and damage the camshaft.

Rotate inlet camshaft against direction of rotation until lettering (1) on 8th cylinder points upwards in cylinder axis and cam is horizontal.

Fig 1: Identifying Lettering On 8th Cylinder On Inlet Camshaft

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Rotate eccentric shaft at dihedral head as illustrated in order to reduce tension on torsion spring (1).

Pretension torsion spring (1) with a cable strap (2), feed out from roller (3) and carefully relieve tension.

Fig 2: Aligning Eccentric Shaft

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IMPORTANT: Do not mix up the camshaft bearing covers of cylinders 1 to 4 and 5 to 8.

NOTE: Bearing caps of inlet camshaft are marked on cylinder bank 5 to 8 with R E1 to R E5 from inlet side.

Release nuts and remove bearing cap R E1.

Fig 3: Identifying Bearing Cap R E1

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Release 8 nuts of bearing bracket (1) from outside to inside.

Fig 4: Locating Nuts Of Bearing Bracket

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NOTE: Rocker arms are freely accessible after bearing bracket has been removed.

Do "not" remove rocker arm (1) on inlet side.

IMPORTANT: Rockers arms (1) are divided into individual tolerance classes. The tolerance classes are designated as illustrated with the numbers from 1 to 4. Used rocker arms (1) may only be reused in the same position.

When replacing rocker arms (1) on inlet side: install rocker arms of the same tolerance class in the same position.

Fig 5: Identifying Rocker Arm

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Clamp special tool 11 9 470 as illustrated in a vise.

Fig 6: Clamping Special Tool 11 9 470 In A Vise

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IMPORTANT: Do not tilt bearing bracket (1).

Carefully lift out bearing bracket (1).

Fig 7: View Of Bearing Bracket

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Place bearing bracket (1) with inlet camshaft and eccentric shaft as illustrated on special tool 11 9 470.

Secure bearing bracket (1) with a nut (special tool 11 9 473)

Fig 8: Placing Bearing Bracket On Special Tool

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IMPORTANT: The lower section of the bearing bracket (1) is machined with the cylinder head and must not be mixed up.

NOTE: Lower section of bearing bracket (1) remains on cylinder head.

Fig 9: Identifying Lower Section Of Bearing Bracket

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NOTE: The mounting of the bearing bracket described later can only be carried out if the inlet camshaft has not been axially displaced. Special tools 11 9 472 and 11 9 475 prevent the inlet camshaft from rotating and moving while the intermediate levers are installed.

Fit special tool 11 9 472 and secure with special tool 11 9 475.

Fig 10: View Of Special Tool 11 9 472 And Guide Bushes

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Insert special tool 11 9 474 and initially tighten without play.

Fig 11: Identifying Special Tool 11 9 474

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NOTE: Removal of intermediate levers is described on 8th cylinder. The same procedure is applicable to cylinders 5 to 7.

Raise one end of torsion spring (1) with special tool 11 9 480.

Lift out intermediate lever (2) and set down in an orderly fashion.

IMPORTANT: Keep holding torsion spring (1) with special tool 11 9 480.

Fig 12: Raising Torsion Spring With Lever

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Attach special tool 11 9 490 to end of torsion spring. Support end of torsion spring protected with special tool 11 9 490 on inlet camshaft.

Fig 13: View Of Holding Sleeve On Torsion Spring

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IMPORTANT: Intermediate levers (2) are divided into individual tolerance classes. Only intermediate levers of the same tolerance class may be fitted in a single cylinder head. The tolerance classes are designated as illustrated with the numbers from 1 to 5. Used intermediate levers (2) may only be reused in the same position.

Fig 14: Identifying Intermediate Levers

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Raise second end of torsion spring (1) with special tool 11 9 480.

Lift out intermediate lever (2) and set down in an orderly fashion.

IMPORTANT: Keep holding torsion spring (1) with special tool 11 9 480.

Fig 15: Securing Torsion Spring With Lever

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Attach special tool 11 9 490 to second end of torsion spring. Support end of torsion spring protected with special tool 11 9 490 on inlet camshaft.

Fig 16: Aligning Torsion Spring Using Holding Sleeve

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Installation:

Removal of intermediate levers is described separately from installation.

Clean all bearings and cams of inlet camshaft and lubricate with engine oil.

Lubricate all sliding surfaces on intermediate lever (2) with engine oil.

Fig 17: Identifying Tolerance Number On Intermediate Levers

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Raise torsion spring (1) with special tool 11 9 480. Detach special tool 11 9 490.

Fig 18: Raising Torsion Spring With Lever

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Hold torsion spring (1) with special tool 11 9 480.

Install intermediate lever (2) from above. Insert end of torsion spring (1) into guide on intermediate lever (2).

Fig 19: Installing Intermediate Lever

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Raise second end of torsion spring with special tool 11 9 480. Detach special tool 11 9 490.

Fig 20: Raising Second End Of Torsion Spring With Lever

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Hold torsion spring (1) with special tool 11 9 480. Install intermediate lever (2) from above.

Insert end of torsion spring (1) into guide on intermediate lever (2).

Fig 21: Installing Intermediate Lever

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Remove special tool 11 9 474.

Fig 22: Removing Support Retaining Screws

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Remove special tools 11 9 472 and special tools 11 9 475.

Fig 23: Removing Guide Bushes

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Ends of compression rings (1) point upwards.

Make sure compression rings (1) are engaged at ends.

Fig 24: Identifying Compression Ring Ends

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IMPORTANT: Rocker arms (1) slip slightly when bearing bracket is fitted. Make sure rocker arms (1) are secured as illustrated on hydraulic valve clearance compensating elements and on valves.

Align rocker arms (1) straight.

Fig 25: Locating Rocker Arms

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Remove special tool 11 9 473.

Remove bearing bracket (1) from special tool 11 9 470.

Fig 26: View Of Bearing Bracket In Support

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IMPORTANT: Do not tilt bearing bracket (1).

Lower bearing bracket (1) from above and carefully bring into contact with cylinder head.

Insert nuts and tighten by hand without play.

IMPORTANT: Make sure none of the intermediate levers or rocker arms have slipped out.

Tighten down nuts from inside to outside.

Tightening torque, refer to 11 31 1AZ in ENGINE - TIGHTENING TORQUES - 545I (4.4L) E60 .

Fig 27: Locating Nuts Of Bearing Bracket

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IMPORTANT: Do not mix up the camshaft bearing covers of cylinders 1 to 4 and 5 to 8.

Fit bearing cap R E1 in such a way that marking is legible from inlet side.

Install nuts and tighten down.

Tightening torque, refer to 11 31 1AZ in ENGINE - TIGHTENING TORQUES - 545I (4.4L) E60 .

Fig 28: Identifying Bearing Cap R E1

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Rotate eccentric shaft at dihedral head as illustrated in order to reduce tension on torsion spring (1).

Pretension torsion spring (1) with a cable strap (2) and carefully fit on roller (3).

Fig 29: Aligning Eccentric Shaft

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Rotate eccentric shaft at dihedral head as shown in illustration back to minimum stroke position.

Fig 30: Aligning Eccentric Shaft To Minimum Stroke Position

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Rotate inlet camshaft in direction of rotation until cam on 5th cylinder points upwards at an angle as shown in illustration.

Fig 31: View Of Inlet Camshaft

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Install inlet and exhaust adjustment unit on right side. Refer to 11 36 047 REMOVING AND INSTALLING/REPLACING INLET AND EXHAUST ADJUSTMENT UNITS ON LEFT SIDE (N62/N62TU) .

Install spark plugs on cylinder bank 5 to 8.

Install left cylinder head cover. Refer to 11 12 005 REMOVING AND INSTALLING/SEALING LEFT CYLINDER HEAD COVER (N62/N62TU) .

Install ignition coils on cylinder bank 5 to 8.

Install servomotor for left eccentric shaft. Refer to 11 37 022 REMOVING AND INSTALLING/REPLACING SERVOMOTOR FOR LEFT ECCENTRIC SHAFT (N62/N62TU) .

Assemble engine.