Rod, Piston And Connecting: Removal: Removal

Fig 1: Identifying Lift Chain

Courtesy of CHRYSLER GROUP, LLC

NOTE:

Pistons, rings, and rods are serviced as an assembly.

CAUTION:

To maintain engine balance, 1, 3, or 4 pistons can be replaced. If 2 pistons are replaced, engine will be out of balance.

Remove engine. Refer to REMOVAL .
Remove engine from lift chain (1) and place on a suitable engine stand.
Remove cylinder head. Refer to CYLINDER HEAD, REMOVAL .

Fig 2: Oil Drain Plug
Courtesy of CHRYSLER GROUP, LLC
Drain engine oil (2).
Remove oil pan (1). Refer to PAN, OIL, REMOVAL .

Fig 3: Oil Filter
Courtesy of CHRYSLER GROUP, LLC
Remove oil filter (1).
Remove balance shaft assembly.
Remove ladder frame.
NOTE:
Remove any carbon build up and clean debris from cylinder prior to piston removal to avoid scratching piston skirts.
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 .

Fig 4: Identifying Mark On Connecting Rod And Bearing Cap
Courtesy of CHRYSLER GROUP, LLC
Rotate crankshaft so that each connecting rod is centered in cylinder bore.
Using a permanent ink or paint marker, identify cylinder number on each connecting rod cap.
CAUTION:
DO NOT use a number stamp or a punch to mark connecting rods, as damage to connecting rod could occur.

CAUTION:
Care must be taken not to damage the fractured rod and cap joint surfaces, as engine damage may occur.
Remove connecting rod bolts and cap.
CAUTION:
Do not reuse connecting rod bolts. These are one-time-use bolts and reuse could result in engine failure.
Carefully push each piston and rod assembly out of cylinder bore. Re-install bearing cap on the mating rod.
Repeat procedure for each piston and connecting rod assembly.