Removing and Installing/Replacing Intermediate Levers

11 37 010 - Removing and installing/replacing intermediate lever (N12)





Special tools required:





Warning!
Danger of injury!

A special tool is essential for opening the return spring on the intermediate lever.





Necessary preliminary tasks:
- Remove cylinder head cover Service and Repair.





Important!
Release screw with special tool only.





Position special tool 11 9 571 on bearing block of balancing shaft so that it rests on intermediate shaft (see arrows).

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





Clamp return spring with knurled screw (1).





Make sure return spring is correctly seated on special tool 11 9 571 (see arrow).





When special tool 11 9 571 is correctly positioned, return spring (2) can be pressed back with lever (1).





Press lever (1) in direction of arrow on special tool 11 9 571 until locking hook (2) engages on special tool 11 9 571.





Warning!
Risk of injury! at return spring.

Locking hook (1) must engage on special tool 11 9 571 (see arrow).





Release screw (1).





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





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





Set down special tool 11 9 571 on special tool 11 9 572 (see arrow).





Warning!
Risk of injury! at return spring.

Release locking hook (1) on special tool 11 9 571.

Release lever (2) in direction of arrow.





Release knurled screw (1) in direction of arrow.

Remove return spring (2).

Set all return springs down on special tool 11 4 480 in a tidy and orderly fashion.





Release screw (2).

Release centering bolt (1).

Remove locating plate and set down on special tool 11 4 480 in a tidy and orderly fashion.





Note:
Screw (1)

Setscrew (2).

Installation Note:
Observe screwing sequence





Remove intermediate lever (3) towards top and set down on special tool 11 4 480 in a tidy and orderly fashion.

Installation Note:
Uniform distribution must not be changed.





All intermediate levers are classified.

Values of 0 to 5 are installed.

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





Installation Note:
Installation of intermediate levers.

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





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





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





Warning!
Risk of injury! at torsion spring.

Locking hook (1) must engage on special tool 11 9 571 (see arrow).





Insert intermediate levers (3).

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





Installation Note:
Make sure rollers of intermediate lever are correctly guided 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°.





Pretension guide block (1) with special tool 11 9 573.

Secure setscrews of guide block (1).

Tightening torque: 11 37 1AZ Mechanical Specifications.

Secure screw on guide block (1).

Tightening torque: 11 37 2AZ Mechanical Specifications.





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





Secure screw (1) of return spring.

Tightening torque: 11 37 3AZ. Mechanical Specifications





Installation Note:
Insert return spring (2) in intermediate lever (1) (see arrow).

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





Remove all special tools.

Assemble engine.