Installing all pistons with connecting rod

NOTE: The description is for one component only. The procedure is identical for all further components.

Installing the piston with the connecting rod

NOTE: RISK OF DAMAGE
Damage on the cylinder wall and oil spray nozzles.
A large force can scratch the cylinder wall and bend the oil spray nozzles.

Carefully shift the piston and connecting rod in the engine block.

Aligning piston rings

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Align the contact points of all piston rings twisted by 120° each.

The piston ring gaps must not be positioned in line with the axis of the piston pin (A).

Piston ring	Alignment
Lower oil scraper ring (O3)	12 o'clock position (1)
Spring (O2)	4 o'clock position (2)
Upper oil scraper ring (O1)	8 o'clock position (3)
Central piston ring (K2)	12 o'clock position (1)
Upper piston ring (K1)	4 o'clock position (2)

Make sure that the spring (O2) does not overlap the piston ring gap (1).

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Insert connecting rod bearing shell (2) at the top in connecting rod (1).
Apply a light coat of oil to the connecting rod bearing shell (2).

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Coat the pistons (1) and piston rings lightly with oil.

Insert the piston (1) with the piston rings into special tool (connector) 0 495 373 (11 6 240) .
Screw special tool 2 463 755 on at large connecting rod eye (2).

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Align the piston so that the arrow (1) points to cylinder 1.
Insert the piston with the connecting rod into the special tool 0 495 373 (11 6 240) and guide it into the cylinder.

NOTE: RISK OF DAMAGE
Damage on the cylinder wall and oil spray nozzles.
A large force can scratch the cylinder wall and bend the oil spray nozzles.

Carefully shift the piston and connecting rod in the engine block.

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Push in piston by hand with only little force. Do not use striking tools.

Install the lower connecting rod bearing

Vacuum the connecting rod bearing shell and cracked surface (1) with a vacuum cleaner (2).

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Insert the connecting rod bearing shell (1) into the connecting rod bearing cap (2).
Apply a light coat of oil to the connecting rod bearing shell (1).

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If necessary, screw special tool (inlet guide) 2 463 755 into the large connecting rod eye.
Pull the connecting rod up to the connecting rod bearing journal.

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NOTE: RISK OF DAMAGE
Engine damage caused by incorrectly installed bearing shells and bearing brackets.
If the bearing shells and bearing brackets are installed incorrectly, then engine damage can occur.

Always install all bearing shells and bearing brackets in the same position from which they were removed.

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Attach the connecting rod bearing caps to the connecting rod until the designations (1) match.
Replace screws (1).
Parts: screw
Tighten the bolts with the special tool 0 490 504 (00 9 120) .

TIGHTENING TORQUES SPECIFICATION

Connecting rod bearing cap to connecting rod
Replace screws. Tighten screws crosswise.	Joining torque	20 Nm
	1. Angle of rotation	70°
	2. Angle of rotation	70°

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Follow-up work

Refer to INSTALLING THE OIL DEFLECTOR
Refer to INSTALL THE OIL VACUUM PUMP .
Refer to REFITTING ENGINE OIL PAN .
Refer to INSTALLING STARTER MOTOR
Refer to INSTALL THE ACOUSTIC COVER FOR THE OIL SUMP .
Refer to SEAL THE OIL DUCT .
Refer to CLEAN SEALING SURFACES .
Refer to INSTALLING THE CYLINDER HEAD GASKET .
Refer to BLOCKING THE CRANKSHAFT IN THE TDC FIRING POSITION OF CYLINDER 1 .
Refer to INSTALLING THE CYLINDER HEAD .
Refer to ADJUSTING THE CAMSHAFTS WITH THE SPECIAL TOOL .
Refer to INSTALLING THE INTAKE ADJUSTER .
Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
Refer to INSTALL EXHAUST CAMSHAFT ADJUSTER .
Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
Refer to PRE-TENSIONING THE TIMING CHAIN WITH THE SPECIAL TOOL .
Refer to TIGHTENING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
Refer to TIGHTENING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
Refer to DISASSEMBLING ALL SPECIAL TOOLS
Refer to INSTALL CHAIN TENSIONER .
Refer to CHECKING THE TIMINGS OF THE CAMSHAFT .
Refer to INSTALLING THE COOLANT LINE BETWEEN THE CYLINDER HEAD AND THE COOLANT PUMP .
Refer to INSTALLING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
Refer to INSTALLING CYLINDER HEAD COVER .
Refer to INSTALLING BOTH ACTUATORS .
Refer to PREPARE THE INJECTORS FOR INSTALLATION .
Refer to INSTALLING THE HIGH-PRESSURE RAIL WITH INJECTORS OF THE CYLINDERS 4 TO 6 .
Refer to INSTALLING RAIL WITH INJECTORS OF CYLINDERS 1 TO 3 .
Refer to INSTALLING THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE PUMP AND THE HIGH-PRESSURE RAIL .
Refer to INSTALLING HIGH PRESSURE PUMP .
Refer to INSTALLING FUEL DELIVERY LINE .
Refer to REPLACE SPARK PLUGS (540i 2017-2020) , or INSTALLING ALL SPARK PLUGS (540i 2021-2022) .
Refer to INSTALL ALL IGNITION COILS .
Refer to INSTALL CATALYTIC CONVERTER .
Refer to INSTALLING THE OXYGEN SENSOR MONITOR .
Refer to INSTALLING LAMBDA OXYGEN SENSOR .
Refer to INSTALLING THE INTAKE PLENUM .
Refer to INSTALLING THE TANK VENT VALVE .
Refer to INSTALLING ACOUSTIC COVER AT REAR .
Refer to TOPPING UP THE MOTOR OIL .
Refer to OPENING THE OIL FILLER CAP .
Refer to REMOVING THE ENGINE FROM THE ASSEMBLY JIG .
Refer to MOUNTING THE ENGINE ON THE FRONT AXLE .
Refer to INSTALLING THE COMPLETE FRONT AXLE INCLUDING ENGINE AND TRANSMISSION .