11 31... Service solution - replacing intake camshaft (N20)

Special tools required:

WARNING: Risk of injury in event of incorrect use.

IMPORTANT: Improper handling. Risk of damage!

Necessary preliminary tasks:

Removal:

NOTE: Injector shafts shown removed for purposes of clarity.

IMPORTANT: Secure eccentric shaft (1) with open-end spanner (3) (risk of return stroke).

Fig 1: Adjusting Eccentric Shaft Using Hexagon Socket Wrench And Open-End Spanner

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Slowly adjust eccentric shaft (1) to minimum lift via servomotor using 4-mm hexagon socket wrench (2) and open-end spanner (3).

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.

Fig 2: Removing Oil Spray Nozzle From Actuator Drive Bracket

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

Fig 3: Positioning Special Tool (11 7 110) On Return Spring

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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 gate.

Fig 4: Turning Knurled Screw

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

Fig 5: Identifying Preloaded Return Spring

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IMPORTANT: Risk of damage!

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

Fig 6: Positioning Return Springs 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.

Fig 7: Preloading Return Spring With Lever On Special Tool (11 7 110)

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

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

Fig 8: Locking Special Tool (11 7 110) With Catch On Lever

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Release screw (1).

Fig 9: Releasing Screw

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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.

Fig 10: Pressing Back Latching Hook Using Special Tool (11 7 110)

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

Fig 11: Releasing Knurled Screw On Special Tool (11 7 110)

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

Fig 12: Releasing Special Tool (11 7 110) From Return Spring

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Return springs (1) remain on the engine.

Fig 13: Identifying Return Springs

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NOTE: All bearing caps are identified with numbers from 1 to 4.

The front bearing cap is a thrust bearing and does not have an identification.

Release screws on all bearing caps (1 to 10).

Set down all bearing caps in a tidy and orderly fashion on special tool 11 4 481 .

Fig 14: Right Intake Camshaft Bearing Cap Bolts Tightening/Loosening Sequence (N20)

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IMPORTANT: Do not remove intermediate levers (1). Mixing up the intermediate levers (1) will cause the engine to suffer idle-speed fluctuations.

Remove intake camshaft.

Fig 15: Identifying Intermediate Levers

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Installation:

IMPORTANT:

Marks of intake and exhaust camshafts are different.

Mixing up the intake and exhaust camshaft will result in engine damage .

A = Exhaust camshaft.

E = Intake camshaft.

Fig 16: Identifying Intake And Exhaust Camshafts Marks

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Insert intake camshaft so that data code (1) on mounting flats points upwards.

Fig 17: Identifying Camshaft Data Code

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Position intake camshaft so that cams point downward at an angle and to the left.

Fig 18: Positioning Intake Camshaft With Cams Pointing Downward At Angle Toward Left

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NOTE: All bearing caps are identified with numbers from 1 to 4.

The front bearing cap is a thrust bearing and does not have an identification.

Insert screws on all bearing caps from (10) to (1).

Tightening torque 11 31 3AZ .

Fig 19: Right Intake Camshaft Bearing Cap Bolts Tightening/Loosening Sequence (N20)

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Position special tool 11 7 110 on return spring.

Fig 20: Releasing Special Tool (11 7 110) From Return Spring

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

Fig 21: Clamping Throttle Return Spring With Knurled Screw

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

Fig 22: Positioning Return Spring

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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.

Fig 23: Pressing Special Tool (11 7 110) To Stop

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Install return spring (2) on gate.

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

Fig 24: Inserting Return Spring In Intermediate Lever

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IMPORTANT: Check that intermediate lever (1) is installed in correct position on eccentric shaft (2).

Fig 25: Identifying Intermediate Lever And Eccentric Shaft

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IMPORTANT: Observe thread on cylinder head. Risk of damage!

Tighten bolt (1).

Tightening torque 11 37 2AZ .

Fig 26: Releasing Screw

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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.

Check installation position of intermediate lever and return spring again , remove special tool 11 7 110 .

Fig 27: Pressing Back Latching Hook Using Special Tool (11 7 110)

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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 .

Fig 28: Removing Oil Spray Nozzle From Actuator Drive Bracket

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Required follow-up work:

Install INTAKE ADJUSTER .

Adjust VALVE TIMING .

Fit CYLINDER HEAD COVER .

Install DME CONTROL UNIT .