Removing and installing/replacing intermediate levers (S55 engine)

Special tools required: 

• 11 4 450
• 11 4 481
• 11 7 110

Necessary preliminary work: 

• Remove INTAKE PLENUM .
• Remove the RAIL HIGH PRESSURE PUMP .
• Remove CYLINDER HEAD COVER .
• Remove all IGNITION COILS AND INJECTOR SHAFTS .

Slowly adjust eccentric shaft in direction of arrow to minimum stroke via the servomotor with a 4-mm hexagon socket wrench (2) and an open-end spanner (1).

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Release bolt (1) on the oil spray nozzle.

Tightening torque: 11 37 4AZ .

Unclip oil spray nozzle (2) from the bracket on the actuator drive (3) in direction of arrow.

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

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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 gate.

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

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

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Preload return spring with lever (1) on special tool 11 7 110 in direction of arrow.

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Lock special tool 11 7 110 with catch on lever (1).

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Release screw (1).

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Secure lever (1).

Press back latching hook (2).

Return spring tension can now be released.

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Release knurled screw (1) on special tool 11 7 110 in direction of arrow.

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Release special tool 11 7 110 in direction of arrow from return spring (1).

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Press return spring (1) apart.

Remove return spring (1) upward.

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

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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 arms with HVCA elements (set out in order)
8. Return 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. 

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Installation note: 

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

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Lift out intermediate levers (1).

Place all intermediate levers (1) in neat order in special tool 11 4 481.

Installation note: 

Mixing up the intermediate levers (1) will cause the engine to suffer idle-speed fluctuations.

Installation note: 

All contact surfaces must be clean and free of oil and grease. If necessary, clean contact surfaces.

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All intermediate levers are classified.

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

Intermediate levers are classified from 1 to 5.

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Install intermediate levers (1).

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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.

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Secure special tool 11 4 450 on screw connection (1) of eccentric shaft and set adjusting screw on special tool 11 4 450 if necessary.

Turn eccentric lever on special tool 11 4 450 in direction of arrow.

Gate is now preloaded.

Insert screws (1) of gates.

Tightening torque 11 37 1AZ .

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Installation note: 

At cylinder no. 3, the gate can be pre-installed with one screw (internal) only.

Oil spray nozzle is fitted only after return spring has been installed.

Press return spring (1) apart.

Install return spring (1).

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Install return spring (2) on gate.

Installation note: 

Insert return spring (2) in intermediate lever (1) (see arrow in illustration).

Check that rocker arm (3) is in correct installation position.

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Position special tool 11 7 110 on return spring.

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

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Return spring (1) is positioned correctly when latching hooks surround return spring (1).

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

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Tighten bolt (1).

Tightening torque 11 37 2AZ .

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Retract oil spray nozzle (2) on actuator drive (3).

Engage bolt (1) and release back to 90°.

For exact positioning of the oil spray nozzle (2) audibly clip it in at the top.

Tightening torque 11 37 4AZ .

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Assemble engine.