Removing and Installing/Replacing Left Intermediate Levers (N62 from 9/03 and N62TU)

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

Special tools required:
- 11 9 470 11 9 470 Support
- 11 9 472 11 9 470 Support
- 11 9 473 11 9 470 Support
- 11 9 474 11 9 470 Support
- 11 9 475 11 9 470 Support
- 11 9 480 11 9 480 Lever
- 11 9 490 11 9 490 Holding Sleeve

(cylinder bank 5 to 8)

Removal of intermediate levers is described separately from installation.

Necessary preliminary tasks:
- Remove servomotor for left eccentric shaft 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 [1][2]Removing and Installing/Sealing Left Cylinder Head Cover
- Remove spark plugs on cylinder bank 5 to 8
- Remove left inlet and exhaust adjustment units 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.

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

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.

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

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

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

Important!
Rocker 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.

Clamp special tool 11 9 470 11 9 470 Support as illustrated in a vice.

Important!
Do not tilt bearing bracket (1).

Carefully lift out bearing bracket (1).

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

Secure bearing bracket (1) with a nut (special tool 11 9 473 11 9 470 Support).

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.

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 11 9 470 Support and 11 9 475 11 9 470 Support prevent the inlet camshaft from rotating and moving while the intermediate levers are installed.

Fit special tool 11 9 472 11 9 470 Support and secure with special tool 11 9 475 11 9 470 Support.

Insert special tool 11 9 474 11 9 470 Support and initially tighten without play.

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 11 9 480 Lever.

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

Important!
Keep holding torsion spring (1) with special tool 11 9 480 11 9 480 Lever.

Attach special tool 11 9 490 11 9 490 Holding Sleeve to end of torsion spring.

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

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.

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

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

Important!
Keep holding torsion spring (1) with special tool 11 9 480 11 9 480 Lever.

Attach special tool 11 9 490 11 9 490 Holding Sleeve to second end of torsion spring.

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

Installation:

Installation of intermediate levers is described separately from removal.

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

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

Remove special tool 11 9 490 11 9 490 Holding Sleeve.

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

Install intermediate lever (2) from above.

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

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

Remove special tool 11 9 490 11 9 490 Holding Sleeve.

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

Install intermediate lever (2) from above.

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

Remove special tool 11 9 474 11 9 470 Support.

Remove special tools 11 9 472 11 9 470 Support and special tools 11 9 475 11 9 470 Support.

Ends of compression rings (1) point upwards.

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

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 rockers (1) straight.

Remove special tool 11 9 473 11 9 470 Support.

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

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 11 31 1AZ 11 31 Camshaft.

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 11 31 1AZ 11 31 Camshaft.

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.

Install inlet and exhaust adjustment unit on left side 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 [1][2]Removing and Installing/Sealing Left Cylinder Head Cover.

Install ignition coils on cylinder bank 5 to 8.

Install servomotor for left eccentric shaft Removing and Installing / Replacing Servomotor for Left Eccentric Shaft (N62/N62TU).

Assemble engine.