Removing and Installing/Replacing Intermediate Levers

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







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.







Clamp throttle return spring with knurled screw (1).







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







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







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.







WARNING: Danger of injury. at return spring.

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







Release screw (1).







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







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







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







WARNING: Danger of injury. at return spring.

Release safety hook (1) at special tool 11 9 571.
Release lever (2) in direction of arrow.







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.







Release screw (2).
Release centring bolt (1).
Remove retaining plate and put onto special tool 11 4 480 in an orderly and tidy fashion.







NOTE:
Screw (1)
Setscrew (2).

Installation note:
Observe screwing sequence







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.







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







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







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







WARNING: Danger of injury at torsion spring.

Safety hook (1) must engage at 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 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°.







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.







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







Secure screw (1) of return spring.
Tightening torque: 11 37 3 AZ.







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.







Remove all special tools.
Assemble engine.