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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 cylinder head (Refer to ENGINE/CYLINDER HEAD - REMOVAL)  .
  2. Remove oil pan (Refer to ENGINE/LUBRICATION/OIL PAN - REMOVAL)  .
  3. Remove Balance Shaft Carrier Assembly (Refer to BALANCE SHAFTS AND CARRIER ASSEMBLY ).
  4. 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  .
    Fig 1: Piston Markings
    GC0021224Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA
  5. Pistons have a directional stamping in the front half of the piston facing towards the front  of engine. See Fig 1.
  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. Using a permanent ink or paint marker, identify cylinder number on each connecting rod cap. See Fig 2.
    CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur.
  8. 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.
  9. 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.
  10. 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.
  11. Repeat procedure for each piston and connecting rod assembly.
  12. Remove piston rings (Refer to ENGINE/ENGINE BLOCK/PISTON RINGS - REMOVAL)  .
Fig 2: Marking Connecting Rod & Bearing Cap Position
GC0003926Courtesy of DAIMLERCHRYSLER CORP.
Fig 3: Connecting Rod Guides
GC0015336Courtesy of DAIMLERCHRYSLER CORP.
1 - SPECIAL TOOL 8189 CONNECTING ROD GUIDES
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