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Piston & Connecting Rod: Removal

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect negative cable from battery.
  2. Remove the following components:
    1. Oil pan and gasket/windage tray (Refer to ENGINE/LUBRICATION/OIL PAN - REMOVAL) .
    2. Cylinder head covers (Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL ).
    3. Timing chain cover (Refer to ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL ).
    4. Cylinder head(s) (Refer to ENGINE/CYLINDER HEAD - REMOVAL) .
  3. If necessary, 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 and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so the each connecting rod is centered in cylinder bore.
    CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur
    Fig 1: Marking Connecting Rod And Bearing Cap Positions
    GC0003989Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.
  4. Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool. See Fig 1.
    CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.
    Fig 2: Identifying Connecting Rod Proper Installation
    GC0003990Courtesy of DAIMLERCHRYSLER CORP.
    1 - WIDE SIDE
    2 - NARROW SIDE
  5. Remove connecting rod cap. Install Special Tool 8507 Connecting Rod Guides into the connecting rod being removed. Remove piston from cylinder bore. Repeat this procedure for each piston being removed.
    CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur
  6. Immediately after piston and connecting rod removal, install bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.
  7. Carefully remove piston rings from piston(s), starting from the top ring down.
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