Piston & Connecting Rod: Installation

WARNING: This page is about a different car, the 2003 Dodge Intrepid, 2003 Chrysler Intrepid, 2003 Chrysler Concorde, and 2003 Chrysler 300M. However, it is still accessible from the selected car via links, so may be relevant.

Install the piston rings. (Refer to INSTALLATION ).
NOTE: The connecting rod bearing cap bolts must be examined before reuse. If the threads are necked down, the bolts must be replaced.
Check connecting rod bolts for necking by holding a scale or straight edge against the threads. If all threads do not contact the scale, the bolt must be replaced (Fig 1).

Fig 1: Checking For Stretched Bolts
Courtesy of DAIMLERCHRYSLER CORP.
Before installing pistons and connecting rod assemblies into the bore, ensure that compression ring gaps are staggered so that neither is in line with oil ring rail gap (Fig 2).

Fig 2: Identifying Piston Ring End Gap Position
Courtesy of DAIMLERCHRYSLER CORP.
Immerse the piston head and rings in clean engine oil, slide the ring compressor over the piston and tighten with the special wrench (Fig 3). Ensure position of rings does not change during this operation.

Fig 3: Installing Piston
Courtesy of DAIMLERCHRYSLER CORP.
Install connecting rod bolt protectors on rod bolts (Figure).
Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal.
CAUTION: Do Not interchange piston assemblies cylinder-to-cylinder or bank-to-bank.

NOTE: Valve reliefs were removed from the pistons for the 2003MY. It is possible when ordering a service piston/rod assembly that valve reliefs are present. These may be used in the engine, and will not affect engine operation.
The arrow on top of piston must be pointing toward front of engine (Fig 4) and oil squirt hole on connecting rod faces the major thrust (right) side of the cylinder bore (Fig 5).

Fig 4: Identifying Piston Orientation
Courtesy of DAIMLERCHRYSLER CORP.

Fig 5: Identifying Piston And Connecting Rod Positioning (Front View Of Engine)
Courtesy of DAIMLERCHRYSLER CORP.
Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal.
Install rod caps. Install nuts on cleaned and oiled rod bolts and tighten nuts to 54 N.m (40 ft. lbs.) Plus 1/4 turn.
Install the cylinder head(s) (Refer to INSTALLATION ).
Install the oil pan. (Refer to INSTALLATION ).