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11 25 530 Removing and installing/replacing all pistons (S62)

WARNING: This page is about a different car, the 2003 BMW Z8, 2002 BMW Z8, 2001 BMW Z8, and 2000 BMW Z8. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required: 

(engine removed)

Removal 

Removal of pistons is described separately from installation. Assembly sequence for removal and installation is different.

Mount engine on special tool 00 1 450 and remove both cylinder heads. Refer to 11 12 517 Removing and installing both cylinder heads (S62) .

Remove lower oil sump section.

Remove oil circuit changeover valve on left and right. Refer to 11 13 540 Removing and installing/replacing left oil circuit changeover valve (S62)  and 11 13 550 Removing and installing/replacing right oil circuit changeover valve (S62) .

In the E52 Series, the oil pump is removed with the upper oil sump section. The procedure is described in the work step Removing and installing upper oil sump section. Refer to 11 13 010 Removing and installing/replacing upper oil sump section (S62) .

CAUTION: Reinstall piston, connecting rod and bearing shells back in the same position and in the same installation location.
Conrod and conrod bearing cover are designated with same pair number: do not interchange / confuse.

In event of heavy oil carbon residue:

Carefully remove oil carbon residue from cylinder wall.

Fig 1: Removing Oil Carbon Residue
G03205181Courtesy of BMW OF NORTH AMERICA, INC.
CAUTION: When the pistons are removed and installed, there is the risk that the piston-cooling spray nozzles may be damaged.

If necessary, remove piston-cooling spray nozzles.

Fig 2: Identifying Piston-Cooling Spray Nozzle
G03205182Courtesy of BMW OF NORTH AMERICA, INC.

Remove connecting-rod cover.

Fig 3: Removing Connecting-Rod Cover
G03205183Courtesy of BMW OF NORTH AMERICA, INC.

Insert special tool 11 3 480 in conrod.

Remove connecting rod with piston from cylinder-head side.

Fig 4: Removing Connecting Rod With Piston
G03205184Courtesy of BMW OF NORTH AMERICA, INC.
CAUTION: Piston and piston bolts are paired and must not be fitted individually.

Lift out retaining ring and press out piston pin.

Fig 5: Removing Retaining Ring And Piston Pin
G03205185Courtesy of BMW OF NORTH AMERICA, INC.

Installation 

Installation of pistons is described separately from removal. The assembly sequence for removal and installation is different.

If necessary, replace connecting rods.

NOTE: The conrods can also be replaced individually.
The piston pin must be able to be pressed through the liner by hand with little force and must not display any significant play.
Fig 6: Installing Piston Pin
G03205186Courtesy of BMW OF NORTH AMERICA, INC.

Prior to installation, measure piston installation clearance:

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

Measuring point A. Refer to 11 25 PISTONS WITH RINGS AND PINS S62 .

Fig 7: Measuring Piston Diameter
G03205187Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 8: Measuring Cylinder Bore
G03205188Courtesy of BMW OF NORTH AMERICA, INC.

Diameter of cylinder bore. Refer to 11 11 ENGINE BLOCK, CYLINDER CRANKCASE S62 .

Piston installation clearance. Refer to 11 25 PISTONS WITH RINGS AND PINS S62 .

Total permissible wear tolerance. Refer to 11 25 PISTONS WITH RINGS AND PINS S62 .

CAUTION: The pistons of cylinder banks 1 to 4 and 5 to 8 are different.

Fit conrod with piston pin to piston so that supplementary weight (1) on conrod points to inlet side.

Fig 9: Installing Conrod
G03205189Courtesy of BMW OF NORTH AMERICA, INC.
NOTE: The direction in which the pairing numbers on the conrod point does not affect the function.

Install conrod bearing. Refer to 11 24 571 Replacing all conrod bearings (S62) .

Install retaining ring.

Fig 10: Installing Retaining Ring
G03205190Courtesy of BMW OF NORTH AMERICA, INC.

Insert special tool 11 3 480 in conrod.

Fig 11: Inserting Special Tool In Conrod
G03205191Courtesy of BMW OF NORTH AMERICA, INC.

Lightly coat pistons and piston rings with oil.

Offset the contact points of the piston rings by approx. 120° to each other but do not position above the piston pin boss.

Press together piston rings using special tool 11 7 180.

Fig 12: Pressing Together Piston Rings
G03205192Courtesy of BMW OF NORTH AMERICA, INC.

Keep piston rings pressed with special tool 11 7 180.

Fig 13: Installing Piston
G03205193Courtesy of BMW OF NORTH AMERICA, INC.

Install piston so that arrow points to camshaft drive.

CAUTION: Danger of piston ring failure.
Only press pistons into place with finger force - do not knock in!

Attach crankpin to connecting rod.

Fig 14: Attaching Crankpin To Connecting Rod
G03205194Courtesy of BMW OF NORTH AMERICA, INC.

Apply light coat of oil to connecting-rod bearing shells.

Fit bearing caps so that pair numbers match up.

Install new connecting-rod screws.

Fig 15: Installing Bearing Caps
G03205195Courtesy of BMW OF NORTH AMERICA, INC.

Secure conrod with special tool 00 9 120.

Tightening torque 11 24 1AZ. Refer to 11 24 CONNECTING RODS AND BEARINGS .

Fig 16: Securing Conrod
G03205196Courtesy of BMW OF NORTH AMERICA, INC.

Install piston-cooling spray nozzles, tighten down banjo bolts.

Tightening torque 11 11 7AZ. Refer to 11 11 ENGINE BLOCK .

Fig 17: Installing Piston-Cooling Spray Nozzles
G03205197Courtesy of BMW OF NORTH AMERICA, INC.
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