11 25 530 Removing and installing/replacing all pistons (N54, N54T)

Special tools required:

WARNING: Protective goggles must be worn when working on the piston pin circlip.

IMPORTANT: If pistons, connecting rods and bearing shells are reused, they must be reinstalled in the same places.
Individual connecting rod replacement is not permitted; they are classified by weight class.
Connecting rods and connecting rod bearing caps are marked with the same pairing letters; mixing them up will result in engine damage.
Piston and gudgeon pins are paired and must not be fitted individually.

Necessary preliminary tasks

Remove ENGINE .
Mount engine on ASSEMBLY STAND .
Remove intake PLENUM .
Remove CYLINDER HEAD .
Remove OIL SUMP .
Remove OIL PUMP .

NOTE: In event of heavy oil carbon residue:

Carefully remove oil carbon residue from cylinder wall.

NOTE: Graphic shows N46.

Fig 1: Locating Cylinder Wall Oil Carbon Residue

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Do not release screw (1).

OIL SPRAY NOZZLE (2) must not be maladjusted or bent.

If necessary, readjust (risk of damage) .

Fig 2: Identifying Oil Spray Nozzle And Screw

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Release connecting rod bolts (1).

Tightening torque: 11 24 1AZ .

Remove connecting rod bearing cap (2) in direction of arrow.

IMPORTANT: Connecting rods and connecting rod bearing caps are marked with the same pairing letters; mixing them up will result in engine damage.

Fig 3: Identifying Connecting Rod Bearing Cap & Bolts

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Screw special tool 11 8 590 into big end of connecting rod.

Press out connecting rod and piston to cylinder head side.

IMPORTANT: Risk of damage to oil spray nozzle.

Fig 4: Pressing Out Connecting Rod And Piston

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Preliminary work

Secure special tool 11 8 561 in vice.

Secure piston (1) with connecting rod to special tool 11 8 561 .

Fig 5: Securing Special Tool (11 8 561) In Vice

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WARNING: Safety goggles must be worn for the next operation.

WARNING: Safety goggles must be worn.

To lever out piston circlip (1), support with special tool 11 5 464 on piston (2).

Lever out piston circlip (1) with special tool 11 5 464 in direction of arrow.

Fig 6: Removing Piston Circlip Using Special Tool (11 5 464)

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Installation note:

If necessary, replace connecting rods.

IMPORTANT: Connecting rods are divided into weight classes and are only available as a set.
Old and new connecting rods must not be installed in mixed combinations.

Installation note:

The gudgeon pin must be able to be pressed through the bush by hand with little force and must not display any significant play.

Fig 7: Locating Connecting Rods

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Measuring Piston Installation Clearance. See 1125 PISTONS WITH RINGS AND PINS (N54) .

Measure piston diameter with micrometer at measuring point A from lower edge of piston and offset at 90° to the axis of the gudgeon pin.

Piston diameter at measuring point A.

Fig 8: Measuring Piston Diameter Using Micrometer

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Adjust micrometer to cylinder bore of engine block. Set internal measuring device on micrometer to zero. Measure bottom, center and top of cylinder bore in direction of travel and direction of rotation.

Diameter of cylinder bore.

Piston installation clearance.

Total Permissible Wear Tolerance. See 1125 PISTONS WITH RINGS AND PINS (N54) .

Installation note:

If necessary, replace piston.

Fig 9: Measuring Cylinder Bore Diameter

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WARNING: Safety goggles must be worn.

IMPORTANT: The opening of the piston pin circlip must be installed on the piston in the 6 o'clock position.
Risk of damage!

Insert piston circlip (2) into groove of special tool 11 8 562 .

Bring piston circlip (2) into working position (1).

Fig 10: Inserting Piston Circlip Into Special Tool Groove (11 8 562)

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WARNING: Safety goggles must be worn.

Slide on special tool 11 8 563 up to piston pin circlip (2)

Special tools 11 8 562 and 11 8 563 are prepared.

Fig 11: Identifying Special Tool (11 8 562) And (11 8 563)

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WARNING: Safety goggles must be worn.

Opening on special tool 11 8 562 must point to piston crown; only then can special tool 11 8 563 be fitted correctly.

If the special tools 11 8 562 and 11 8 563 are not positioned correctly, the piston pin circlip must be driven in using a plastic hammer in direction of arrow.

NOTE: See Fig 12.

Fig 12: Positioning Special Tool (11 8 562) And (11 8 563)

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Piston pin circlip is correctly installed when opening (1) points downwards.

Fig 13: Identifying Piston Pin Circlip Hole

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NOTE: B 30.

Install all PISTON RINGS .

Install all BEARING SHELLS .

Coat piston and piston rings with oil.

Pre-install piston (2) in special tool 11 8 141 .

Screw on special tool 11 8 590 in connecting rod (2).

Installation note:

Make sure protective lugs (1) on special tool 11 8 590 are positioned correctly and check for damage.

Fig 14: Installing Piston In Special Tool (11 8 141)

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Insert piston with connecting rod in cylinder.

IMPORTANT: Risk of damage to oil spray nozzle.
Risk of breakage of piston rings.
Press in piston in direction of arrow with finger pressure only, do not drive in.

Insert piston so that arrow on piston crown points to camshaft drive.

Press in piston (1) with special tool 11 8 141 .

Fig 15: Inserting Piston With Connecting Rod In Cylinder

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IMPORTANT: Connecting rod and connecting rod bearing cap are marked with pairing letters (1) and must not be mixed up.
Swapping or incorrectly fitting the connecting rod bearing cap on the big end will result in engine damage.

Fig 16: Identifying Connecting Rod And Connecting Rod Bearing Cap Pairing Letters