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Piston And Connecting Rod

WARNING: This page is about a different car, the 2007 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Piston Ring End Gap Positions
GC0004179Courtesy of CHRYSLER LLC
1 - GAP OF LOWER SIDE RAIL
2 - NO. 1 RING GAP
3 - GAP OF UPPER SIDE RAIL
4 - NO. 2 RING GAP AND SPACER EXPANDER GAP
  1. Install piston rings on piston. Refer to INSTALLATION .
  2. Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. See Fig 1.
  3. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown in. See Fig 1. As viewed from top.
    Fig 2: Installing Piston
    GC0021087Courtesy of CHRYSLER LLC
  4. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston. See Fig 2. Be sure position of rings does not change during this operation  .
    Fig 3: Identifying Piston Markings
    GC0042813Courtesy of CHRYSLER LLC
    1 - DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA
    NOTE: If installing used piston/rod assembly, they must be installed in their original position.
  5. The directional stamp (1) on the piston should face toward the front of the engine. See Fig 3.
  6. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Lubricate connecting rod journal with clean engine oil.
    Fig 4: Connecting Rod Guides
    GC0015336Courtesy of CHRYSLER LLC
  7. Install connecting rod upper bearing half into connecting rod. Install Connecting Rods Guides 8189 (1) onto connecting rod. See Fig 4.
  8. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal.
  9. Remove Connecting Rod Guides 8189.
    NOTE: The connecting rod cap bolts should not be reused.
  10. Before installing the NEW  bolts, the threads should be coated with clean engine oil.
  11. Install connecting rod lower bearing half into connecting rod cap. Install connecting rod cap.
  12. Install each bolt finger tight then alternately torque each bolt to assemble the cap properly.
  13. Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the following values:
    CAUTION: Do not use a torque wrench for the second step.
    1. Tighten the bolts to 27 N.m (20 ft. lbs.).
    2. Tighten the connecting rod bolts an additional 1/4 TURN. 
    Fig 5: Checking Connecting Rod Side Clearance - Typical
    GC0021091Courtesy of CHRYSLER LLC
  14. Using a feeler gauge, check connecting rod side clearance. See Fig 5. Refer to SPECIFICATIONS  for connecting rod side clearance.
  15. Install Balance Shaft Carrier Assembly. See INSTALLATION .
    Fig 6: View Of Oil Pan
    GC0042814Courtesy of CHRYSLER LLC
    1 - OIL FILTER
    2 - OIL PAN GASKET
    3 - OIL PAN
    4 - ADAPTER GASKET
    5 - OIL FILTER ADAPTER
  16. Install oil pan (3). Refer to INSTALLATION .
  17. Install cylinder head. Refer to INSTALLATION .
  18. Start engine and check for leaks.
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