11 37 010 Removing and installing/replacing intermediate levers (B48, B46)

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Special tools required:

WARNING: Risk of injury in event of incorrect use.

Attention !

Risk of damage in event of incorrect use.

Necessary preliminary tasks:

Removal:

NOTE: Special tool 2 359 088 consists of two parts:

Torsion spring clamping lever
Fixture (fitting aid) for clamping lever

Fig 1: Torsion Spring Clamping Lever And Fixture (Fitting Aid) For Clamping Lever

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Secure intake camshaft with an open-end spanner (1).

Release screw (2).

Remove sensor wheel (3).

Fig 2: Securing Intake Camshaft With Open-End Spanner

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Slowly adjust eccentric shaft (1) to minimum lift via servomotor (2) using a 4 mm hexagon socket wrench.

Fig 3: Adjusting Eccentric Shaft To Minimum Lift Via Servomotor

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NOTE: The cam (1) of the intake camshaft must not contact on the intermediate lever when removing the torsion spring.
Rotate engine further as necessary with special tool 11 6 480 .

Fig 4: Cam Of Intake Camshaft

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Attention!

Do not crank engine in reverse direction!

Position special tool 2 359 088 on torsion spring (1).

Attention !

The special tool must lie flat on the cylinder head.

Fig 5: Positioning Special Tool (2 359 088) On Torsion Spring

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Attention !

Risk of damage !

Both torsion springs (1) on the left and right must be positioned in the lateral guide of special tool 2 359 088 .

Fig 6: Positioning Torsion Springs In Lateral Guide Of Special Tool (2 359 088)

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WARNING: Risk of injury in event of incorrect use.

Attention !

Improper handling. Risk of damage !

Preload return spring with lever (1) on special tool 2 359 088 in direction of arrow.

Fig 7: Preloading Return Spring With Lever On Special Tool (2 359 088)

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Lock special tool 2 359 088 with catch on lever (1).

Fig 8: Locking Special Tool (2 359 088) With Catching On Lever

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Carefully lift special tool 2 359 088 .

Feed special tool 2 359 088 with torsion spring (1) out of cylinder head (2).

Fig 9: Feeding Special Tool (2 359 088) With Torsion Spring Out Of Cylinder Head

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WARNING: Risk of injury in event of incorrect use.
Clamping lever (1) is preloaded.

Attention !

Improper handling. Risk of damage !

Secure fixture (2) for clamping lever in vice.

Fig 10: Securing Fixture For Clamping Lever In Vice

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Position clamping lever (1) with torsion spring in fixture (2).

Carefully unlock and slowly open clamping lever (1).

Remove torsion spring.

Set down all torsion springs neatly in special tool 11 4 480 .

Release screw (1) of gate (2).

Place all gates (2) in neat order in special tool 11 4 480 .

Fig 11: Gate And Screw

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Remove all intermediate levers (1).

Place all intermediate levers (1) in neat order in special tool 11 4 480 .

Fig 12: Removing Intermediate Levers

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Installation:

Attention !

Before installing intermediate levers, make sure rocker arms (1) are correctly positioned.

Risk of damage !

Fig 13: Rocker Arm

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Installation note:

All intermediate levers are classified.

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

Fig 14: Intermediate Lever Classification

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Intermediate levers are classified from 1 to 5.

Only one classification may be fitted per engine.

Insert all intermediate levers (1).

Fig 15: Removing Intermediate Levers

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Installation note:

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

Fig 16: Contact Surfaces Of Gates

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Mount gate (2) neatly.

Tighten screw (1) hand-tight.

Check that intermediate levers are in correct installation position.

Fig 17: Gate And Screw

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Position the special tool 2 359 089 on the cylinder head.

Pre-tension the gate with the lever (3).

Abut the screw (1) in the area (2).

Make sure that the special tool 2 359 089 does not rotate during this process.

Fig 18: Positioning Special Tool (2 359 089) On Cylinder Head

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Secure the gate with the lever (1) in the direction of arrow.

Fig 19: Securing Gate With Lever

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Attention !

Special tool 2 359 089 must lie flat on the cylinder head.

Fig 20: Installing Special Tool (2 359 089) On Cylinder Head

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Press the special tool 2 359 089 onto the cylinder head.

Tighten the screw (1) at the same time.

Tightening torque 11 37 1AZ .

Fig 21: Pressing Special Tool (2 359 089) Onto Cylinder Head

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NOTE: Special tool 2 359 088 consists of two parts:

(1) Torsion spring clamping lever
(2) Fixture (fitting aid) for clamping lever

Fig 22: Torsion Spring Clamping Lever And Fixture (Fitting Aid) For Clamping Lever

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Clamp special tool (2) in vice.

Engage torsion spring (3) in clamping lever (1).

Fig 23: Engaging Torsion Spring In Clamping Lever

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Attention !

Danger of injury !

Make sure torsion spring (3) is correctly positioned in clamping lever (1).

Fig 24: Torsion Spring And Clamping Lever

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Attention !

Risk of damage !

Both torsion springs (1) on the left and right must be positioned in the lateral guide of special tool 2 359 088 .

Ensure correct engagement of clamping lever.

Fig 25: Torsion Springs

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Lift clamping lever (1) with torsion spring out of fixture (2).

Fig 26: Lifting Clamping Lever With Torsion Spring Out Of Fixture

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Insert special tool 2 359 088 with torsion spring (1) into cylinder head (2).

Fig 27: Feeding Special Tool (2 359 088) With Torsion Spring Out Of Cylinder Head

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Engage torsion spring (2) in intermediate lever (1).

Check that all rocker arms (3) are in correct installation position.

Fig 28: Torsion Spring, Intermediate Lever And Rocker Arms

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The special tool 2 359 088 must rest plane against the cylinder head.

WARNING: Risk of injury in event of incorrect use.

Attention !

Improper handling. Risk of damage !

Carefully unlock clamping lever (1).

Fig 29: Locking Special Tool (2 359 088) With Catching On Lever

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Check torsion spring on intermediate lever to ensure correct installation position.

Ensure correct position of torsion spring in recess on cylinder head.

Fig 30: Locating Torsion Spring

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Secure intake camshaft with an open-end spanner (1).

Position sensor wheel (3).

Tighten down screw (2).

Tightening torque 11 31 7AZ .

Fig 31: Securing Intake Camshaft With Open-End Spanner

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