11 25 530 Removing and installing / replacing all pistons (M62): Installation

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2003 BMW 540i, 2002 BMW 540i, 2001 BMW 540i, 2000 BMW 540i, and 1999 BMW 540i. However, it is still accessible from the selected car via links, so may be relevant.

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 1: Checking Piston Pin

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Before installation, measure piston installation clearance. Measure piston diameter with micrometer at measuring point A from bottom edge of piston and offset at 90° to the axis of the piston pin.

Measuring point A.

Fig 2: Measuring Piston Diameter With Micrometer

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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.

Piston installation clearance.

Total permissible wear tolerance.

Fig 3: Measuring Cylinder Bore

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Install conrod bearing.

IMPORTANT: Piston and piston bolts are paired and must not be fitted individually.

Fit conrod with piston pin to piston in such a way that both of the visible pair numbers on the installation direction arrow on the piston point to the right.

Fig 4: Fitting Conrod With Piston Pin

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Install retaining ring.

Fig 5: Installing Retaining Ring

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Install special tool 11 2 470 in conrod.

Fig 6: Installing Special Tool 11 2 470 In Conrod

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M62 B46 only:

Lightly coat pistons and piston rings with oil.

Align contact points of piston rings (offset at approx. 120°, but not over piston pin lug).

Compress piston rings with special tool 11 9 500.

Keep piston rings compressed with special tool 11 9 500.

Install piston so that arrow points to camshaft drive.

Fig 7: Keeping Piston Rings Compressed With Special Tool 11 9 500

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IMPORTANT: Danger of piston ring failure.
Press in piston only with finger force (do not knock in!).

M62 B35 / B44 only:

Lightly coat pistons and piston rings with oil.

Align contact points of piston rings (offset at approx. 120°, but not over piston pin lug).

Press together piston rings using special tool 11 2 260.

Fig 8: Pressing Together Piston Rings Using Special Tool 11 2 260

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Install piston so that arrow points to camshaft drive.

Entire circumference of tightening strap must rest firmly on engine block.

IMPORTANT: Danger of piston ring failure.
Press in piston only with finger force (do not knock in!).

Fig 9: Installing Piston With Finger Force

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Attach crankpin to connecting rod.

Fig 10: Attaching Crankpin To Connecting Rod

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

Fit bearing caps so that pair numbers match up.

Install new conrod bolts.

Fig 11: Fitting Bearing Caps

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Tighten down conrod bearing with special tool 00 9 120 or with special tool 11 2 110.

Tightening torque, refer to 11 24 1AZ in ENGINE - TIGHTENING TORQUES - 540i .

Fig 12: Tightening Down Conrod Bearing With Special Tool 00 9 120

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Install spray nozzle and tighten down screw.

Fig 13: Installing Spray Nozzle And Tighten Down Screw

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