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ROD, Piston and Connecting: Removal: Removal

WARNING: This page is about a different variant/trim than selected.
Fig 1: Battery System Components & PDC Cover
GC0080006Courtesy of CHRYSLER LLC
  1. Perform the fuel system pressure release procedure. Refer to Fuel System/Fuel Delivery - Standard Procedure .
  2. Disconnect and isolate the negative battery cable (3).
    Fig 2: Removing/Installing Engine Covers
    GC0080281Courtesy of CHRYSLER LLC
  3. Remove the engine covers (1).
    Fig 3: Air Duct To Throttle Body
    GC0094861Courtesy of CHRYSLER LLC
  4. Loosen clamp and disconnect the air duct at throttle body.
  5. Disconnect the intake air temperature sensor (4) electrical connector.
  6. Remove the makeup air hose (1).
  7. Remove the air cleaner housing retaining bolt (3) and remove the air cleaner housing (2).
  8. Remove the cylinder head(s). See Engine/Cylinder Head - Removal .
  9. Raise and support the vehicle.
    Fig 4: Engine Mount Nuts
    GC0094862Courtesy of CHRYSLER LLC
  10. Remove the engine mount nuts (1, 2).
    Fig 5: Gear Mounting Bolts
    GC0080538Courtesy of CHRYSLER LLC
  11. Remove the steering gear mounting bolts (1) and position the steering gear (2) aside.
  12. Remove the engine oil dipstick and tube from the oil pan.
  13. Lower the vehicle.
    Fig 6: Engine Lift Fixture & Adapter
    GC0094863Courtesy of CHRYSLER LLC
    NOTE: Do not use air tools to install engine lift fixture.
  14. Install the Engine Lift Fixture 8984A (1), Engine Lift Adapter 8984-UPD (2) and the Engine Support Fixture 8534B (3).
  15. Raise the engine to provide clearance to remove the oil pan.
  16. Raise and support the vehicle.
  17. Remove the oil pan. See Engine/Lubrication/PAN, Oil - Removal .
  18. Lower the vehicle.
  19. Remove the timing chain cover. See Engine/Valve Timing/COVER(S), Engine Timing - Removal .
  20. If necessary, remove the ridge on top of the cylinder bores with a reliable ridge reamer before removing the pistons from the cylinder block. Be sure to keep the tops of the pistons covered during this operation. 
    Fig 7: Identify Conn Rod To Cylinder
    GC0081782Courtesy of CHRYSLER LLC
    CAUTION: Do Not use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur.
    NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removal to ensure correct reassembly.
  21. Raise and support the vehicle.
  22. Mark the connecting rod and bearing cap positions using a permanent ink marker or scribe tool.
    Fig 8: Connecting Rod Guides
    GC0094864Courtesy of CHRYSLER LLC
    CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.
    CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur.
    NOTE: Pistons and connecting rods assemblies must be removed from the top of cylinder block. When removing the piston and connecting rod assemblies from the engine, rotate the crankshaft so each connecting rod is centered in the cylinder bore.
  23. Remove the connecting rod cap, install the Connecting Rod Guides 8507 (1) and carefully remove the piston from the cylinder bore, repeat this procedure for each piston being removed.
  24. Immediately after removing the piston and connecting rod, install the bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.
  25. Carefully remove the piston rings from the piston(s), starting from the top ring down.
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