11 37 012 Removing and installing/replacing left intermediate levers (N62 from 9/03 and N62TU)

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 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

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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 2: View Of Bearing Cap R E1

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

Fig 3: 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 4: Identifying Tolerance Classes On Rocker Arm

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

Fig 5: Clamping Support In A Vise

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IMPORTANT: Do not tilt bearing bracket (1).

Carefully lift out bearing bracket (1).

Fig 6: 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 7: Securing Bearing Bracket With Nut

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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 8: 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 9: Fitting Special Tool And Securing With Guide Bushes

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

Fig 10: Identifying Retaining Screws

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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 11: Raising Torsion Spring Using 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 12: Supporting End Of Torsion Spring Using Holding Sleeve

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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 13: Identifying Tolerance Classes On 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 14: Removing Intermediate 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 15: Supporting End Of Torsion Spring Using Lever

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Installation:

Installation of intermediate levers is described separately from removal.

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 16: Identifying Tolerance Classes On Intermediate Levers

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

Detach special tool 11 9 490.

Fig 17: Raising Torsion Spring Using 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 18: Installing Torsion Spring Into Guide On 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 19: 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 20: Installing Torsion Spring Into Guide On Intermediate Lever

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Remove special tool 11 9 474.

Fig 21: View Of Support Retaining Screws

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

Fig 22: Identifying Guide Bushes

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Ends of compression rings (1) point upwards.

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

Fig 23: Locating 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 24: Aligning Rocker Arms

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Remove special tool 11 9 473.

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

Fig 25: Removing Bearing Bracket From 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 26: Locating Bearing Bracket Nuts

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IMPORTANT: Camshaft bearing caps of cylinders 1 to 4 and 5 to 8 must not be mixed up.

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 27: View Of Bearing Cap R E1

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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.

NOTE: The marking (1) on the hexagon drive of the inlet camshaft faces upwards.

Fig 28: Identifying Marking On Hexagon Drive Of Inlet Camshaft

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Install 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) .

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.