11 37 010 Removing and installing/replacing intermediate levers (N16)

Special tools required:

WARNING: Risk of injury!
A special tool is essential for opening the return spring on the intermediate lever.

Necessary preliminary tasks:

Remove CYLINDER HEAD COVER .

IMPORTANT: Release screw with special tool only.11 9 571

Fig 1: Warning -- Only Release Screw Using Special Tool 11 9 571

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Position special tool 11 9 571 at bearing support of counterbalance shaft so that it is resting on intermediate shaft (see arrows).

Set eccentric shaft (1) to minimum lift if necessary.

Fig 2: Positioning Special Tool (11 9 571) At Counterbalance Shaft Bearing Support

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Clamp throttle return spring with knurled screw (1).

Fig 3: Clamping Throttle Return Spring With Knurled Screw

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Throttle return spring at special tool 11 9 571 , pay attention to correct seating (see arrow).

Fig 4: Checking For Correct Seating Of Throttle Return Spring At Special Tool

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If the special tool 11 9 571 is correctly position, the throttle return spring (2) can be pushed back using lever (1).

Fig 5: Pushing-Back Throttle Return Spring Using Lever

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Push lever (1) in direction of arrow at special tool 11 9 571 until the safety hook (2) engages at the special tool 11 9 571 .

Fig 6: Pushing Lever On Special Tool (11 9 571)

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WARNING: Danger of injury! at return spring.

Safety hook (1) must engage at special tool 11 9 571 (see arrow).

Fig 7: Securing Safety Hook At Special Tool (11 9 571)

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Release screw (1).

Fig 8: Identifying Screw

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Prepare special tool 11 9 572 in a vice (1).

Fig 9: Securing Special Tool (11 9 340) Into Cylinder Head

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Feed out special tool 11 9 571 with the torsion spring (1).

Fig 10: Identifying Special Tool (11 9 571) And Torsion Spring

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Place special tool 11 9 571 onto special tool 11 9 572 .

Fig 11: Positioning Special Tool (11 9 571) Onto Special Tool (11 9 572)

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WARNING: Danger of injury! at return spring.

Release safety hook (1) at special tool 11 9 571 .

Release lever (2) in direction of arrow.

Fig 12: Releasing Safety Hook At Special Tool (11 9 571)

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Release knurled screw (1) in direction of arrow.

Remove return spring (2).

Place all throttle return springs onto special tool 11 4 480 in an orderly and tidy fashion.

Fig 13: Removing Return Spring

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Release screw (2).

Release centering bolt (1).

Remove retaining plate and put onto special tool 11 4 480 in an orderly and tidy fashion.

Fig 14: Identifying Centering Bolt And Screw

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NOTE: Screw (1)
Setscrew (2).

Installation note:

Observe screwing sequence

Fig 15: Identifying Screw And Setscrew

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Remove intermediate lever (3) from above and put down onto special tool 11 4 480 in an orderly and tidy fashion.

Installation note:

Uniform distribution must not be changed.

Fig 16: Identifying Intermediate Lever

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All intermediate levers are classified.

Values of 0 to 5 are installed.

NOTE: A uniform distribution can only be calculated with the diagnosis tester.

Fig 17: Identifying Intermediate Lever Classification Mark

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Installation note:

Installation of intermediate levers.

Position torsion spring (1) onto special tool 11 9 571 (see arrows) and clamp using knurled screw.

Fig 18: Positioning Torsion Spring Onto Special Tool (11 9 571)

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Press torsion spring (1) in direction of arrow and position at special tool 11 9 571 with lever.

Fig 19: Pressing Torsion Spring

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Pre-tension torsion spring (1) with special tool 11 9 571 in direction of arrow.

Fig 20: Pre-Tensioning Torsion Spring With Special Tool (11 9 571)

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WARNING: Danger of injury! at torsion spring.

Safety hook (1) must engage at special tool 11 9 571 (see arrow).

Fig 21: Securing Safety Hook At Special Tool (11 9 571)

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Insert intermediate levers (3).

Installation note:

Make sure roller cam followers (2) are in correct installation position.

Fig 22: Identifying Intermediate Lever

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Installation note:

Make sure that rollers of intermediate lever are correctly guided on/in guide block.

Install guide block.

Insert setscrew (1).

Insert bolt (2).

Join screws (1 and 2) to 5 Nm.

Release screws (1 and 2) back by 90°.

Fig 23: Identifying Centering Bolt And Screw

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Pre-tension guide block (1) with special tool 11 9 573 .

Secure setscrews of guide block (1).

Tightening torque: 11 37 1AZ .

Secure screw on guide block (1).

Tightening torque: 11 37 2AZ .

Fig 24: Pre-Tensioning Guide Block Using Special Tool (11 9 573)

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Feed in throttle return spring (1) with special tool 11 9 571 and position.

Fig 25: Identifying Special Tool (11 9 571) And Torsion Spring

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Secure screw (1) of return spring.

Tightening torque: 11 37 3 AZ .

Fig 26: Identifying Screw

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Installation note:

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

Check intermediate lever (1) and roller cam follower (3) again for correct installation position.

Fig 27: Inserting Return Spring Into Intermediate Lever

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Remove all special tools.

Assemble engine.