Removing and Installing/Replacing Intermediate Levers

11 37 010 Removing and installing/replacing intermediate levers (N51)

Special tools required:







IMPORTANT:
Aluminium magnesium materials.
No steel screws/bolts may be used due to the threat of electrochemical corrosion.
A magnesium crankcase requires aluminium screws/bolts exclusively.
Aluminium screws/bolts must be replaced each time they are released.
Aluminium screws/bolts are permitted with and without colour coding (blue).
For reliable identification:
Aluminium screws/bolts are not magnetic.
Jointing torque and angle of rotation must be observed without fail (risk of damage).







NOTE: There are 2 different versions of the gate

IMPORTANT:
Establish size of gates.
Version 1
Size 55.2 mm
Version 2
Size 58 mm
The description of version 2 starts on page 8.







Version 1
Size (1) 55.2 mm







Necessary preliminary tasks:
- Remove cylinder head cover.







If necessary, set eccentric shaft (1) on mounting flats to minimum lift (2).







Secure special tool 11 4 270 with gripping pliers (3) to gate (2).

IMPORTANT:
Special tool 11 4 270 is only secured to gate.
Adjusting the locking pliers (3) is not permitted (risk of damage) on special tool 11 4 270.

NOTE: The oil nozzle must be removed beforehand from cylinder no. 3.







WARNING: Risk of injury in event of incorrect use.

IMPORTANT: Risk of damage in the event of improper handling.

Secure both bearing pins (2) in return spring with knurled screw (1) on special tool 11 4 270.
Press special tool 11 4 270 towards stop in direction of arrow.







Release steel screw (2).
To avoid jamming with screw (2) and return spring, it is necessary when releasing screw (2) to relieve the preload on special tool 11 4 270 uniformly.

IMPORTANT: Risk of damage to cylinder head thread.

Tightening torque: 11 37 2AZ.







Relieve tension on return spring (1) with special tool 11 4 270.

NOTE: Metal tab (2) cannot be disassembled and must not be removed.

Installation note:
Replace metal tab if tab washer is defective.







Press return spring apart at position (1) and remove towards top.







IMPORTANT:
Uniform distribution must not be changed.
All components must be set down in a clean and orderly fashion.

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

1 Eccentric shaft with bearing
2 Bearing caps of eccentric shaft set out in order.
3 Intake camshaft
4 Bearing caps of inlet camshaft set out in order.
5 Intake valves with valve springs
6 Valve heads and valve keys
7 Roller cam follower with hydraulic valve clearance compensating element (set out in order).
8 Return springs.
9 gates set out in order.
10 Intermediate levers set out in order.







Release screws (1).
Tightening torque: 11 37 1AZ.
Set down gates (2) in special tool 11 4 481 in neat order.

Installation note:
Mixing up the gates may cause the engine to demonstrate idle fluctuations.
This will result in maladjustment of uniform distribution.







Installation note:
Contact surfaces (1) must be clean and oil-free.
Clean if necessary.








Lift out intermediate levers (2).
Intermediate levers (2) arranged in special tool 11 4 481

Installation note:
Mixing up the intermediate levers may cause the engine to demonstrate rpm fluctuations.

Installation note:
Contact surfaces (1) must be clean and oil-free.
Clean if necessary.







All intermediate levers (1) are classified.
Reinstall intermediate levers which have already been used in the same positions.







Installation note:
Before reinstalling the intermediate levers, make sure the roller cam followers are correctly positioned (risk of damage).

Install intermediate levers (2).







Fit gate (2) cleanly into opening.
Tighten screws (1) hand-tight.
Check both intermediate levers again to ensure correct installation position.
Release bolts (1) again by a 1/4 turn.







Secure special tool 11 4 450 to screw connection (1) of eccentric shaft.
Move eccentric lever (3) on special tool 11 4 450 in direction of arrow.
gate is now tensioned.
Secure screws (2).
Tightening torque: 11 37 1AZ.

Installation note:
At cylinder no. 3, the gate can be pre-installed with one bolt (2) only.
Fit oil pump only after retaining spring has been fitted.







Fit return spring on gate.

Installation note:
Insert return spring (2) in intermediate lever (1) (see arrow).
Check roller cam follower (3) again to ensure correct installation position.







Secure special tool 11 4 270 with gripping pliers (3) to gate (1).

IMPORTANT:
Special tool 11 4 270 is only secured to gate.
Adjusting the locking pliers (3) is not permitted (risk of damage) on special tool 11 4 270.







WARNING: Risk of injury in event of incorrect use.

IMPORTANT: Incorrect handling risk of damage.

Secure both bearing pins (2) in return spring with knurled screw (1) on special tool 11 4 270.

IMPORTANT: Check return spring again on intermediate lever to ensure correct installation position.

Press special tool 11 4 270 towards stop in direction of arrow.







Insert steel screw (2).
To avoid jamming with screw (2) and return spring, it is necessary when inserting screw (2) to increase the preload on special tool 11 4 270 uniformly.

IMPORTANT: Risk of damage to cylinder head thread.

Tightening torque: 11 37 2AZ.
Remove special tool 11 4 270.







At cylinder no. 3, adjust oil spray nozzle (2) so that oil spray (3) points precisely towards gearing.







Assemble engine.







Version 2
Size (1) 58 mm







Necessary preliminary tasks:
- Remove cylinder head cover







If necessary, move eccentric shaft (1) on mounting flats to minimum lift (2).







NOTE: Oil spray nozzle must be removed from 3rd cylinder (make a note of installation position of oil spray nozzle).







Position special tool 11 7 110 on return spring (1) (see arrows).







WARNING: Risk of injury in event of incorrect use.

IMPORTANT: Improper handling. Risk of damage.

Place special tool11 7 110 flat on cylinder head.
Turn knurled screw (1) in direction of arrow until both clamping levers secure return spring in gate.







Return spring is correctly preloaded when both clamping levers are parallel to guide block.







IMPORTANT: Risk of damage.

Left and right return springs (1) must be positioned in lateral guide of special tool 11 7 110.







Preload return spring with lever (1) on special tool11 7 110 in direction of arrow.







Lock special tool11 7 110 with catch on lever (1).

IMPORTANT: Screw connection on return spring can only be released with special tool 11 7 110 secured.







Release screw (1).







WARNING: Risk of injury in event of incorrect use.

Lever (1) is preloaded.

IMPORTANT:
Improper handling.
Risk of damage.

Secure lever (1).
Press back latching hook (2).
Return spring tension can now be released.







Release knurled screw (1) on special tool11 7 110 in direction of arrow.







Release special tool11 7 110 in direction of arrow from return spring (1).







Press torsion spring apart at positions (1).
Remove torsion spring towards top.







IMPORTANT:
Uniform distribution must not be changed.
Place all components in clean and orderly condition in special tool 11 4 481.

All components must be reinstalled in the same positions in an engine which has already been in use.
1 Eccentric shaft with bearing
2 Bearing caps of eccentric shaft (set out in order)
3 Intake camshaft
4 Bearing caps of intake camshaft (set out in order)
5 Intake valves with valve springs
6 Valve heads and valve keys
7 Rocker arm with hydraulic valve clearance compensating element (set out in order).
8 Torsion springs
9 Gates (set out in order)
10 Intermediate levers (set out in order)







Release screws (1) on gate (2).
Tightening torque 11 37 1AZ.
Place all gates (2) in neat order in special tool 11 4 481.

Installation note:
Mixing up the gates (2) will cause the engine to suffer idle-speed fluctuations.
This will result in maladjustment of uniform distribution.







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







Lift out intermediate levers (2).
Place all intermediate levers (2) in neat order in special tool 11 4 481.

Installation note:
Mixing up the intermediate levers (2) will cause the engine to suffer idle-speed fluctuations.

Installation note:
All contact surfaces (1) must be clean and free from oil and grease. If necessary, clean contact surfaces (1).







All intermediate levers (1) are classified.
All intermediate levers (1) must be reinstalled in the same positions in an engine which has already been in use.







IMPORTANT:
Before installing intermediate levers (2), make sure rocker arms are correctly positioned.
Risk of damage.

Install intermediate levers (2).







Fit gate (2) cleanly into recess.
Tighten screws (1) hand-tight.
Check that intermediate levers are in correct installation position.
Release screws (1) by a 1/4 turn.







Secure special tool 11 4 450 to screw connection (1) of eccentric shaft.
Move eccentric lever (3) on special tool 11 4 450 in direction of arrow.
Gate is now preloaded.
Insert screws (2) of gates.
Tightening torque 11 37 1AZ.

Installation note:
At cylinder no. 3, the gate can be pre-installed with one screw (internal) only.
Oil spray nozzle is fitted only after torsion spring has been installed.







Install torsion spring (2) on gate.

Installation note:
Insert torsion spring (2) in intermediate lever (1) (see arrow).
Check that rocker arm (3) is in correct installation position.







Position special tool11 7 110 on return spring.







Clamp return spring with knurled screw (1) in direction of arrow.







Return spring (1) is positioned correctly when catches (see arrows) are surrounding return spring (1).







WARNING: Risk of injury in event of incorrect use.

IMPORTANT:
Improper handling.
Risk of damage.
Check return spring on intermediate lever to ensure correct installation position.

Press special tool 11 7 110 to stop in direction of arrow.







IMPORTANT:
Pay attention to thread on cylinder head.
Risk of damage.

Tighten bolt (1).
Tightening torque 11 37 2AZ.







At cylinder no. 3, adjust oil spray nozzle (2) so that oil spray points precisely towards gearing (3).
Insert screw (1) with oil spray nozzle (2) (external).
Tightening torque 11 37 4AZ.







Assemble engine.