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Piston & Connecting Rod: Removal

WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the cylinder head (Refer to ENGINE/CYLINDER HEAD - REMOVAL) .
  2. Remove the oil pan (Refer to ENGINE/LUBRICATION/OIL PAN - REMOVAL) .
  3. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation  . Mark piston with matching cylinder number. See Fig 1.
    Fig 1: Piston Markings
    GC0021086Courtesy of DAIMLERCHRYSLER CORP.
    1 - WEIGHT DESIGNATION AND DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA
    CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur.
  4. Using a permanent ink or paint marker, identify cylinder number on each connecting rod cap. See Fig 2.
    Fig 2: Marking Connecting Rod & Bearing Cap Position
    GC0003926Courtesy of DAIMLERCHRYSLER CORP.
  5. Pistons will have a stamping in the approximate location shown in Fig 1. These stamps will be either a directional arrow or a weight identification for the assembly. L is for light and H is for heavy. These assemblies should all be the same weight class. Service piston assemblies are marked with a S and can be used with either L or H production assemblies. The weight designation stamps should face toward the timing belt side of the engine.
  6. Pistons and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each connecting rod is centered in cylinder bore.
  7. Remove connecting rod bolts and cap. Care should be taken not to damage the fracture rod and cap surfaces.
    NOTE: Do not reuse connecting rod bolts.
    CAUTION: Care must be taken not to damage the fractured rod and cap joint surfaces, as engine damage many occur.
  8. To protect crankshaft journal and fractured rod surfaces, install Special Tool 8189, connecting rod guides onto connecting rod. See Fig 3. Carefully push each piston and rod assembly out of cylinder bore.
  9. Remove Special Tool 8189, connecting rod guides and re-install bearing cap on the mating rod.
    NOTE: Piston and rods are serviced as an assembly.
  10. Repeat procedure for each piston and connecting rod assembly.
  11. Remove piston rings (Refer to ENGINE/ENGINE BLOCK/PISTON RINGS - REMOVAL) .
Fig 3: Connecting Rod Guides
GC0015336Courtesy of DAIMLERCHRYSLER CORP.
1 - SPECIAL TOOL 8189 CONNECTING ROD GUIDES
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