Rod-Connecting & Piston: Removal

Fig 1: Oil Pan

Courtesy of DAIMLERCHRYSLER CORP.

1 - OIL FILTER

2 - OIL PAN GASKET

3 - OIL PAN

4 - ADAPTER GASKET

5 - OIL FILTER ADAPTER

Remove cylinder head (Refer to ENGINE/CYLINDER HEAD - REMOVAL) .
Remove oil pan (3) (Refer to ENGINE/LUBRICATION/OIL PAN - REMOVAL) .

Fig 2: Piston Markings
Courtesy of DAIMLERCHRYSLER CORP.

1 - DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA
Remove Balance Shaft Carrier Assembly (Refer to BALANCE SHAFT CARRIER under REMOVAL).
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 .
Pistons have a directional stamping in the front half of the piston facing towards the front of engine. See Fig 2.
Pistons and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each piston is centered in the bore.

Fig 3: Marking Connecting Rod & Bearing Cap Position
Courtesy of DAIMLERCHRYSLER CORP.
Using a permanent ink or paint marker, identify cylinder number on each connecting rod cap. See Fig 3.
CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur.

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 may occur.

Fig 4: Oil Jet Fastener - 2.4L Turbo

Courtesy of DAIMLERCHRYSLER CORP.

1 - FASTENER - 12 N.m (105 in. lbs.)

2 - OIL JET

3 - ENGINE BLOCK

4 - CYLINDER WALL

NOTE: On Turbocharger equipped engines, be careful not to damage the oil jet (2) when removing piston/connecting rod. See Fig 4.

Fig 5: Connecting Rod Guides

Courtesy of DAIMLERCHRYSLER CORP.

1 - CONNECTING ROD GUIDES 8189

To protect crankshaft journal and fractured rod surfaces, install Connecting Rod Guides 8189 onto connecting rod. See Fig 5. Carefully push each piston and rod assembly out of cylinder bore.
Remove Connecting Rod Guides 8189, connecting rod guides and re-install bearing cap on the mating rod.
NOTE: Piston and rods are serviced as an assembly.
Repeat procedure for each piston and connecting rod assembly.
Remove piston rings (Refer to ENGINE/ENGINE BLOCK/PISTON RINGS - REMOVAL) .