11 37 012 Removing and installing/replacing left intermediate lever (S63T 0)

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Special tools required:

2 249 160
2 249 166
Cylinder bank 2

(cylinder bank 5 to 8)

Necessary preliminary tasks:

Remove the engine with front axle. See 31 10 001 COMPLETELY REMOVING AND INSTALLING THE FRONT AXLE WITH ENGINE AND TRANSMISSION (S63T0, MANUAL GEARBOX) or 31 10 001 COMPLETELY REMOVING AND INSTALLING FRONT AXLE WITH ENGINE AND TRANSMISSION (S63T0, DKG) .

Remove LEFT CYLINDER HEAD COVER .

Remove the drive belt for the AIR CONDITIONING COMPRESSOR .

Remove tensioning device for DRIVE BELT .

IMPORTANT: Set intermediate shaft to zero lift.
Turn the intake camshaft to the point where a small amount of tension arises at the intermediate lever.

Adjust intermediate shaft using adjusting screw (1).

Fig 1: Identifying Adjustment Screw Of Intermediate Shaft

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Turn engine at central bolt as needed for removing the intermediate shaft.

Position intake camshaft (2) of the intermediate lever to be mounted in a horizontal position (see arrow in illustration).

Set intermediate shaft (1) to zero lift (see arrow in illustration).

Fig 2: Positioning Intake Camshaft And Setting Intermediate Shaft To Zero Lift

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NOTE: Throttle return spring and special tool do not need to be removed.

Fit special tool 2 249 160 on cylinder head.

Preload throttle return spring with special tool 2 249 160 .

Fig 3: Fitting Special Tool 2 249 160 Onto Cylinder Head

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Loosen the collar bolt (2).

Release retaining screw (3).

Remove gate (1).

Fig 4: Identifying Collar Bolt, Gate, Fixture And Retaining Screw

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Remove roller cam follower (1) toward the top using a magnet.

Fig 5: Identifying Roller Cam Follower

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Installation note:

Make sure roller cam follower is in correct installation position.

Fig 6: Identifying Roller Cam Follower Installation Position

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Position gate (1) on cylinder head.

Insert retaining screw (3) and loosen by 45°.

Insert collar bolt (2) and loosen by 45°.

Fig 7: Identifying Collar Bolt, Gate, Fixture And Retaining Screw

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Position fixture (1) on cylinder head.

Insert retaining screw (3) and loosen by 45°.

Loosen the collar bolt (2).

Fig 8: Identifying Collar Bolt, Gate, Fixture And Retaining Screw

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Position gate (1) on cylinder head.

Insert retaining screw (3) and loosen by 45°.

Insert collar bolt (2) and loosen by 45°.

Fig 9: Identifying Collar Bolt, Gate, Fixture And Retaining Screw

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Using special tool 2 249 166 , press gate upward in direction of arrow to the cylinder head.

Fig 10: Pressing-On Gate Toward Top At Cylinder Head

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Attach retaining screw (3).

Tightening torque: 11 37 2AZ .

Attach collar bolt (2).

Tightening torque: 11 37 2AZ .

Fig 11: Identifying Collar Bolt, Gate, Fixture And Retaining Screw

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Preload special tool 2 249 160 .

Pull up release mechanism (1).

Loosen lock in direction of arrow.

Remove special tool 2 249 160 .

Fig 12: Releasing Screw Of Torsion Spring

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Make sure throttle return spring on roller cam follower (1) is in the correct installation position.

Fig 13: Checking Installation Position Of Throttle Return Spring On Roller Cam Follower

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Installation note:

Assemble engine.