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Piston And Connecting Rod

NOTE: Refer to the connecting rod Description before beginning repair. See DESCRIPTION .
Fig 1: Piston Ring End Gap Position
GC0002127Courtesy of CHRYSLER LLC
1 - SIDE RAIL UPPER
2 - NO. 1 RING GAP
3 - PISTON PIN
4 - SIDE RAIL LOWER
5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
Fig 2: Piston Orientation
GC0001917Courtesy of CHRYSLER LLC
1 - ARROW FACES FRONT OF ENGINE
  1. 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 (1-4) (see Fig 1) and that the arrow on top of the piston (3) is facing the front of the engine, if equipped. See Fig 2.
  2. Before installing the ring compressor, ensure the oil ring expander ends are butted and the rail gaps located as shown in Fig 1.
    Fig 3: Piston and Rod Install - Typical
    GC0002126Courtesy of CHRYSLER LLC
    1 - RING - OIL CONTROL 7 - CAP - CONNECTING ROD
    2 - RING - NO. 2 COMPRESSION 8 - BEARING - CONNECTING ROD LOWER
    3 - RING - NO. 1 COMPRESSION 9 - CRANKSHAFT JOURNAL PROTECTOR (RUBBER HOSE)
    4 - RING - SIDE RAIL UPPER & LOWER 10 - BEARING - CONNECTING ROD UPPER
    5 - PISTON RING COMPRESSOR 11 - PISTON AND CONNECTING ROD ASSEMBLY
    6 - NUT - CONNECTING ROD 12 - PISTON LOCATION MARK (F = FRONT)
  3. Lubricate the piston and rings with clean engine oil. Position a ring compressor over the piston and rings, and tighten the compressor. See Fig 3. Be sure position of rings does not change during this operation. 
  4. Position upper bearing onto connecting rod. Lubricate bearing with oil.
    Fig 4: Installing Piston & Connecting Rod
    GC0001918Courtesy of CHRYSLER LLC
    1 - "F" TOWARD FRONT OF ENGINE
    2 - RING COMPRESSOR
    3 - SPECIAL TOOL 8189
    4 - OIL SQUIRT HOLE
  5. Install connecting rod bolt protectors (rubber hose or equivalent). See Fig 3 on the connecting rod bolts, or use special tool. See Fig 4 #8189 for cracked cap design
    Fig 5: Piston and Connecting Rod Positioning
    GC0002130Courtesy of CHRYSLER LLC
    1 - MAJOR THRUST SIDE OF PISTON
    2 - OIL SQUIRT HOLE
  6. The pistons are marked with a "F" located near the piston pin, or an arrow on top of the piston. Install piston with this mark positioned to front of engine on both cylinder banks. The connecting rod oil squirt hole (2) faces the major thrust (right) side (1) of the engine block. See Fig 5.
  7. Rotate crankshaft until the connecting rod journal is located in the center of the cylinder bore. Insert connecting rod and piston into cylinder bore by tapping down on the piston using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. See Fig 3.
  8. Install lower bearing shell and the appropriate connecting rod cap. See Fig 3.
  9. Install connecting rod cap retaining nuts on cleaned and oiled rod bolts and tighten to 54 N.m (40 ft. lbs.) PLUS 1/4 turn. Install connecting rod bolts and tighten to 7 N.m (5 ft. lbs) initially. Tighten the bolts an additional 21 N.m (15 ft. lbs.) and then turn each bolt 90° to final clamping load.
  10. Repeat procedure for each piston and connecting rod installation.
  11. Install the cylinder heads. See INSTALLATION .
  12. Install the oil pan. See INSTALLATION .
  13. Fill engine crankcase with proper oil to correct level.
  14. Connect negative cable to battery.
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