Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2003 Chrysler Intrepid (CANADA) V6-2.7LFACTORY OEM SERVICE PROCEDURE
Piston, Engine
Pistons
Material Aluminum Alloy
Piston Diameter 85.983 mm ±0.019 (3.3851 inch ±0.0017)
Clearance at Size Location -0.0096 to +0.0436 mm (-0.0003 to +0.0016 in.)
Piston Weight 316-326 grams (11.1466-11.4994 oz.)
Piston Ring Groove Diameter-No. 1 77.8-78 mm (3.063-3.070 in.)
Piston Ring Groove Diameter-No. 2 75.9-76.1 mm (2.988-2.996 in.)
Piston Ring Groove Diameter-No. 3 76.5-76.7 mm (3.011-3.019 in.)
Piston Ring Side Clearance
Compression Ring-Top 0.035-0.083 mm (0.0013-0.0032 in.)
Compression Ring-Second 0.040-0.080 mm (0.0016-0.0031 in.)
Oil Ring (Steel Rails) 0.058-0.204 mm (0.0022-0.0080 in.)
Piston Rings
Ring Gap-Top Compression Ring 0.20-0.36 mm (0.008-0.014 in.)
Ring Gap-2nd Compression Ring 0.37-0.63 mm (0.0146-0.0249 in.)
Ring Gap-Oil Control (Steel Rails) 0.25-0.76 mm (0.010-0.030 in.)
Piston Ring Width
Compression Rings-Top and Second 1.47-1.49 mm (0.0579-0.0587 in.)
Oil Ring (Steel Rails) 0.445-0.470 mm (0.0176-0.0186 in.)
Piston Pins
Type Full Floating
Pin Diameter 21.997-22.000 mm (0.8661-0.8662 in.)
Clearance in Piston 0.005-0.013 mm (0.0002-0.0005 in.)
Clearance in Rod 0.007-0.018 mm (0.0003-0.0008 in.)
Material Aluminum Alloy
Piston Diameter 85.983 mm ±0.019 (3.3851 inch ±0.0017)
Clearance at Size Location -0.0096 to +0.0436 mm (-0.0003 to +0.0016 in.)
Piston Weight 316-326 grams (11.1466-11.4994 oz.)
Piston Ring Groove Diameter-No. 1 77.8-78 mm (3.063-3.070 in.)
Piston Ring Groove Diameter-No. 2 75.9-76.1 mm (2.988-2.996 in.)
Piston Ring Groove Diameter-No. 3 76.5-76.7 mm (3.011-3.019 in.)
Piston Ring Side Clearance
Compression Ring-Top 0.035-0.083 mm (0.0013-0.0032 in.)
Compression Ring-Second 0.040-0.080 mm (0.0016-0.0031 in.)
Oil Ring (Steel Rails) 0.058-0.204 mm (0.0022-0.0080 in.)
Piston Rings
Ring Gap-Top Compression Ring 0.20-0.36 mm (0.008-0.014 in.)
Ring Gap-2nd Compression Ring 0.37-0.63 mm (0.0146-0.0249 in.)
Ring Gap-Oil Control (Steel Rails) 0.25-0.76 mm (0.010-0.030 in.)
Piston Ring Width
Compression Rings-Top and Second 1.47-1.49 mm (0.0579-0.0587 in.)
Oil Ring (Steel Rails) 0.445-0.470 mm (0.0176-0.0186 in.)
Piston Pins
Type Full Floating
Pin Diameter 21.997-22.000 mm (0.8661-0.8662 in.)
Clearance in Piston 0.005-0.013 mm (0.0002-0.0005 in.)
Clearance in Rod 0.007-0.018 mm (0.0003-0.0008 in.)
Factory Service Tools
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.