Operation CHARM: Car repair manuals for everyone.
Home >> Chrysler >> 2001 >> Sebring Coupe V6-3.0L VIN H >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Procedures >> Engine Overhaul >> Piston and Connecting Rod >> Piston and Connecting Rod Removal and Installation

Piston and Connecting Rod Removal and Installation





REMOVAL AND INSTALLATION
Required Special Tool: MIT216941: Piston Pin Setting Tool
Removal Service Points
<> Connecting Rod Cap Removal





1. Mark the cylinder number on the side of the connecting rod big end for correct reassembly.
2. Keep the removed connecting rods, caps, and bearings in order according to the cylinder number.

<> Piston Pin Removal








1. Remove the stop screw from the base.





2. Select the correct piston support for your application. (See above) Fit the piston support onto the base. Place the base on the press support blocks.
3. Insert the press pin through the piston pin hole. Select the correct connecting rod guide pin. (See above.) Thread the guide pin onto the threaded portion of the press pin.
4. Position the piston assembly on the piston support in the press. With the press pin up as shown, insert the guide pin through the hole in the piston and through the hole in the piston support.

CAUTION: To avoid piston damage, the piston support must seat squarely against the piston. Verify that the piston pin will slide through the hole in the piston support.

5. Press the piston pin out of the assembly.
6. Remove the piston pin from the piston pin.

Installation Service Points
>>A<< Piston Pin Installation





1. Thread the stop screw and jam nut assembly into the base. Fit the correct piston support on top of the base. Insert the press pin, threaded end up, into the hole in the piston support until the press pin touches the stop screw.
2. Using the graduations on the press pin, adjust the stop screw to the depth.
Depth: 60 mm (2.36 inches)





3. Place the base on the press support blocks.
4. Slide the piston pin over the threaded end of the press pin, and thread the correct guide pin up against it.
5. Coat the piston pin with engine oil, and with the connecting rod held in position, slide the guide pin through the piston and connecting rod.
6. Press the piston pin through the connecting rod until the guide pin contacts the stop screw.

CAUTION: Due to production tolerance variations, it is necessary to visually inspect the piston pin depth after installation to verify that the piston pin is centered. Adjust if necessary.

7. Remove the piston assembly from the base. Remove the guide pin and press pin from the assembly.





8. Check that the piston moves smoothly.

>>B<< Oil Ring Installation








1. Fit the oil ring spacer into the piston ring groove.

NOTE: The side rails and spacer may be installed in either direction.

NOTE: New spacers and side rails are colored for identification of their sizes.





CAUTION: Do not use any piston ring expander when installing the side rail.

2. Install the upper side rail to install the side rail, first fit one end of the rail into the piston groove, then press the remaining portion into the position by finger. See illustration.
3. Install the lower side rail in the same procedure as described in step 2.
4. Make sure that the side rails move smoothly in either direction.

>>C<< Piston Ring No.2/P1Ston Ring No.1 Installation








1. To prevent wrong installation, check the identification mark of each piston ring. The identification mark is stamped near the ring gap:
Identification mark
Number 1 ring: T
Number 2 ring: 2T

NOTE: Size marks on piston rings are as follows.





2. Using a piston ring expander, fit the number 2 piston ring into the number 2 groove of piston.

NOTE: Install the piston rings with their identification mark facing up, to the piston crown side.

3. Install the number 1 piston ring in the same manner as step 2.

>>D<< Connecting Rod Bearing Installation











1. Measure the crankshaft pin diameter and confirm its classification from the following table. In the case of a crankshaft supplied as a service part, identification colors/ marks of its pins are painted/stamped at the positions shown in the illustration.





2. If the crankshaft pin outside diameter ID color is "yellow" and the connecting rod ID color is "yellow," for example, select a bearing whose ID color is "none." If there is no ID color paint on the crankshaft, measure the pin outside diameter and select a bearing appropriate for the measured value.
3. Install the selected bearing in the big end and in the cap of the connecting rod.

\
>>E<< Piston And Connecting Rod Installation





1. Apply engine oil on the circumference of the piston, piston rings, and oil ring.
2. Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the illustration.
3. Rotate the crankshaft so that the crank pin is on the center of the cylinder bore.





4. Use suitable thread protectors on the connecting rod bolts before inserting the piston and connecting rod assembly into the cylinder block. Care must be taken not to nick the crank pin.
5. Insert the piston and connecting rod assembly into the cylinder with the front mark on the piston crown pointing to the timing belt side.
6. Using a suitable piston ring compressor tool, install the piston and connecting rod assembly into the cylinder block.

>>F<< Connecting Rod Cap Installation





1. Mate the correct bearing cap with the correct connecting rod by checking with the alignment marks marked during disassembly. If a new connecting rod is used which has no alignment mark, position the notches for locking the bearing on the same side.





2. Check if the thrust clearance in the connecting rod big end is correct.
Standard value: 0.10 - 0.25 mm (0.004 - 0.009 inch)
Limit: 0.4 mm (0.02 inch)
pro multis · About Operation CHARM