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11 25 530 Removing and installing/replacing all pistons (N62)

WARNING: This page is about a different car, the 2005 BMW 545i and 2004 BMW 545i. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:

For Special Tool identification, see MAINTENANCE & GENERAL INFORMATION - SPECIAL TOOLS - 5-SERIES (E60) and ENGINE- SPECIAL TOOLS - 5-SERIES (E60) .

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 assembly stand.

Remove both cylinder heads.

Unscrew oil sump.

Remove oil pump.

CAUTION: Re-install piston, connecting rod and bearing shells back in the same position and in the same installation location. Conrods and conrod bearing caps are denoted with the same pairing letters, do not mix them up.

In event of heavy oil carbon residue:

Carefully remove oil carbon residue from cylinder wall.

Fig 1: Identifying Oil Carbon Residue From Cylinder Wall
G03269525Courtesy of BMW OF NORTH AMERICA, INC.
CAUTION: When removing and installing pistons, make sure piston cooling spray nozzles (1) are not damaged.
Fig 2: Identifying Piston Cooling Spray Nozzles
G03269526Courtesy of BMW OF NORTH AMERICA, INC.

Remove connecting-rod cover.

NOTE: Conrods and conrod bearing caps are denoted with the same pairing letters. Set down conrod bearing caps in order.
Fig 3: Locating Connecting Rod Cover Retaining Screws
G03269527Courtesy of BMW OF NORTH AMERICA, INC.

Insert special tools 11 8 151 and 11 8 152 in conrod.

Remove connecting rod with piston from cylinder-head side.

Fig 4: View Of Special Tools 11 8 151/11 8 152
G03269528Courtesy 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
G03269529Courtesy 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: Identifying Piston Pin
G03269530Courtesy 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 ENGINE - TECHNICAL DATA- 545I (4.4L) E60/N62 .

Fig 7: Measuring Piston Installation Clearance
G03269531Courtesy 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.

Diameter of cylinder bore. Refer to ENGINE - TECHNICAL DATA- 545I (4.4L) E60/N62 .

Piston installation clearance. Refer to ENGINE - TECHNICAL DATA- 545I (4.4L) E60/N62 .

Total permissible wear tolerance. Refer to ENGINE - TECHNICAL DATA- 545I (4.4L) E60/N62 .

Fig 8: Measuring Cylinder Bore
G03269532Courtesy of BMW OF NORTH AMERICA, INC.
NOTE: The pistons and conrods of cylinders 1 to 8 are identical.
CAUTION: The conrods of cylinder banks 1 to 4 and 5 to 8 are mounted to the pistons differently.

Cylinder Bank 1 To 4: 

Fit conrod with piston pin to piston in such a way that arrow on piston points to front and flat end of conrod points to rear.

Fig 9: Aligning Conrod With Piston (Cylinder Bank 1 To 4)
G03269533Courtesy of BMW OF NORTH AMERICA, INC.

Cylinder Bank 5 To 8: 

Fit conrod with piston pin to piston in such a way that arrow on piston points to front and flat end of conrod points to rear.

Install conrod bearing. Refer to 11 24 571 REPLACING ALL CONROD BEARINGS (N62/N62TU) .

Fig 10: Aligning Conrod With Piston (Cylinder Bank 5 To 8)
G03269534Courtesy of BMW OF NORTH AMERICA, INC.

Install retaining ring.

Fig 11: Installing Retaining Ring
G03269535Courtesy of BMW OF NORTH AMERICA, INC.

Insert special tools 11 8 151 and 11 8 152 in conrod.

Fig 12: Inserting Special Tools In Conrod
G03269536Courtesy of BMW OF NORTH AMERICA, INC.

N62 B44: 

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.

Compress piston rings with special tool 11 9 500.

Fig 13: Compressing Piston Rings With Special Tool
G03269537Courtesy of BMW OF NORTH AMERICA, INC.

N62 B44: 

Keep piston rings compressed with special tool 11 9 500.

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!

Fig 14: Installing Piston In Bore
G03269538Courtesy of BMW OF NORTH AMERICA, INC.

N62 B36: 

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.

Slide special tool 11 8 141 over piston (1).

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!

Fig 15: View Of Special Tool On Piston
G03269539Courtesy of BMW OF NORTH AMERICA, INC.

Attach crankpin to connecting rod.

Remove special tools 11 8 151 and 11 8 152.

Fig 16: Identifying Special Tools 11 8 151/11 8 152
G03269540Courtesy of BMW OF NORTH AMERICA, INC.
NOTE: For purposes of clarity, the pairing letters (1) are shown on the removed conrod.
CAUTION: Conrods and conrod bearing caps are denoted with the same pairing letters (1), do not mix them up.
Fig 17: Identifying Pairing Letters On Removed Conrod
G03269541Courtesy of BMW OF NORTH AMERICA, INC.

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

Fit bearing cap so that pairing letters match up.

Install new connecting-rod screws.

Fig 18: Installing Connecting-Rod Screws
G03269542Courtesy of BMW OF NORTH AMERICA, INC.

Secure conrod with special tool 00 9 120.

Tightening torque, refer to 11 24 1AZ in ENGINE - TIGHTENING TORQUES - 545I (4.4L) E60 .

Fig 19: Securing Conrod With Torque Angle Measuring Dial
G03269543Courtesy of BMW OF NORTH AMERICA, INC.
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