BIMMERPOST 1137010 Removing and Installing or Replacing Intermediate Levers for BMW E61 525i Instruction Manual
- June 9, 2024
- BIMMERPOST
Table of Contents
BIMMERPOST 1137010 Removing and Installing or Replacing Intermediate
Levers for BMW E61 525i
Product Information
The BMW E61 525i Touring is a high-performance luxury vehicle designed for the ultimate driving experience. The engine of this vehicle is equipped with variable valve gear to optimize performance, and intermediate levers are an essential component of this system. To ensure proper installation and replacement of theseintermediate levers, special tools are required. It is important to note the use of aluminium-magnesium materials in the engine, which require the exclusive use of aluminium screws/bolts to prevent electrochemical corrosion.
Special Tools Required
- 11 4 270
- 11 4 450
- 11 4 481
- 11 7 110
Important Notes
- No steel screws/bolts may be used due to the threat of electrochemical corrosion.
- Aluminium screws/bolts must be replaced each time they are released.
- Jointing torque and angle of rotation must be observed without fail (risk of damage).
- Two versions of the guide blocks are used, and the size must be determined before proceeding.
Product Usage Instructions
- Remove the cylinder head cover, and if necessary, set the eccentric shaft on twin surface to minimum lift.
- Secure special tool 11 4 270 with gripping pliers to guide block.
- Secure both bearing pins in return spring with knurled screw on special tool 11 4 270.
- Release steel screw and relieve tension on return spring with special tool 11 4 270.
- Press return spring apart at position and remove towards the top.
- Release screws and set down guide blocks in special tool 11 4 481 in neat order.
- Ensure that contact surfaces are clean and oil-free before installation.
- Reinstall all components in the same positions in an engine which has already been in use.
It is important to follow these instructions carefully to prevent damage to the engine and ensure optimal performance of the vehicle. If you have any questions or concerns about the usage of these components, consult a professional mechanic or contact BMW customer support for assistance.
**Special tools required
**
- 11 4 270
- 11 4 450
- 11 4 481
- 11 7 110
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:
2 versions of the guide blocks are used
Important!
Determine size of guide blocks.
Version 1
Size: 55.2 mm
Version 2
Size: 58 mm
Description of Version 2 begins on
Removing and installing/replacing intermediate levers (N52)
Version 1
Size (1) 55.2 mm
Necessary preliminary tasks:
- Remove cylinder head cover .
If necessary, set eccentric shaft (1) on twin surface to minimum lift (2).
Note:
Oil spray nozzle must be removed from 3rd cylinder (make a note of
installation position of oil spray nozzle).
Secure special tool 11 4 270 with gripping pliers (3) to guide block
(2).Important!
Special tool 11 4 270 is only secured to guide block.
Adjusting the gripping 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!
Incorrect handling risk of damage .
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 pretension 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
lug (2) cannot be disassembled and must not be removed.
Installation:
Replace metal lug 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.
- Eccentric shaft with bearing
- Bearing caps of eccentric shaft set out in order.
- Intake camshaft
- Bearing caps of inlet camshaft set out in order.
- Intake valves with valve springs
- Valve plates and valve cotters
- Roller cam followers with HVC element set out in order.
- Return springs.
- Guide blocks set out in order.
- Intermediate levers set out in order.
Release screws (1).
Tightening torque: 11 37 1AZ.
Set down guide blocks (2) in special tool 11 4 481 in neat order.
Installation:
Mixing up the guide blocks may cause the engine to demonstrate idle
fluctuations.
This will result in maladjustment of uniform distribution .
Installation:
Contact surfaces (1) must be clean and oilfree.
Clean if necessary.
Lift out intermediate levers (2).
Intermediate levers (2) arranged in special tool 11 4 481 .
Installation:
Mixing up the intermediate levers may cause the engine to demonstrate rpm
fluctuations.
Installation:
Contact surfaces (1) must be clean and oilfree.
Clean if necessary.
All intermediate levers (1) are classified.
Reinstall intermediate levers which have already been used in the same
positions.
Installation:
Before reinstalling the intermediate levers, make sure the roller cam
followers are correctly positioned (risk of damage) .
Install intermediate levers (2).
Fit guide block (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.
Shift eccentric lever (3) on special tool 11 4 450 in direction of arrow.
Guide block is now tensioned.
Secure screws (2).
Tightening torque: 11 37 1AZ.
Installation:
At cylinder no. 3, the guide block can be preinstalled with one bolt (2) only.
Fit oil pump only after retaining spring has been fitted.
Fit return spring on guide block.Installation:
Insert return spring (2) in intermediate lever (1) (see arrow).
Check roller cam follow (3) again to ensure correct installation position.
Secure special tool 11 4 270 with gripping pliers (3) to guide block
(1).Important! Special tool 11 4 270 is only secured to guide block.
Adjusting the gripping 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.
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 pretension 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 nozzle (2) exactly so that oil spray (3) points precisely towards spline teeth.
Assemble engine.
Version 2
Size (1) 58 mm
Necessary preliminary tasks:
- Remove cylinder head cover
If necessary, move eccentric shaft (1) on twin surface 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 tool 11 7 110 flat on cylinder head.
Turn knurled screw (1) in direction of arrow until both clamping levers secure
return spring in guide block.
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 tool 11 7 110 in direction of arrow.
Lock special tool 11 7 110 with latching hook on lever (1).Important!
Screw connection on return spring can only be released with secured special
tool 11 7 110.
Release screw (1).
Warning!
Risk of injury in event of incorrect use.
Lever (1) is under pre-tension.
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 tool 11 7 110 in direction of arrow.
Release special tool 11 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.
- Eccentric shaft with bearing
- Bearing caps of eccentric shaft (set out in order)
- Intake camshaft
- Bearing caps of inlet camshaft (set out in order)
- Intake valves with valve springs
- Valve plates and valve cotters
- Cam followers with HVA elements (set out in order)
- Torsion springs
- Guide blocks (set out in order)
- Intermediate levers (set out in order)
Release screws (1) on guide block (2).
Tightening torque 11 37 1AZ .
Place all guide blocks (2) in neat order in special tool 11 4 481 .
Installation:
Mixing up the guide blocks (2) will cause the engine to suffer idle-speed
fluctuations. This will result in maladjustment of uniform distribution .
Installation:
All contact surfaces (1) of guide block 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:
Mixing up the intermediate levers (2) will cause the engine to suffer idle-
speed fluctuations.
Installation:
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 cam followers are
correctly positioned.
Risk of damage!
Install intermediate levers (2).
Fit guide block (2) cleanly into opening.
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.
Shift eccentric lever (3) on special tool 11 4 450 in direction of arrow.
Guide block is now pretensioned.
Insert screws (2) of guide blocks.
Tightening torque 11 37 1AZ .
Installation:
At cylinder no. 3, the guide block can be preinstalled with one screw
(internal) only.
Oil spray nozzle is fitted only after torsion spring has been installed.
Install torsion spring (2) on guide block.Installation:
Insert torsion spring (2) in intermediate lever (1) (see arrow).
Check that cam follower (3) is in correct installation position.
Position special tool 11 7 110 on return spring.
Clamp return spring with knurled screw (1) in direction of arrow.
Return spring (1) is positioned correctly when latching hooks surround return spring (1) (see arrows).
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 spline teeth (3).
Insert screw (1) with oil spray nozzle (2) (external).
Tightening torque 11 37 4AZ .
Assemble engine.
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References
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