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HOMESERVICE MANUALSCHRYSLER2004PT CRUISER TOURING, 2.4 B, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 101 (2.7L)PISTON & CONNECTING RODINSTALLATION
2004 Chrysler PT Cruiser Touring, 2.4 B, Automatic

Piston & Connecting Rod: Installation

2004 Chrysler PT Cruiser Touring, 2.4 B, AutomaticSECTION Installation
WARNING: This page is about a different car, the 2003 Dodge Intrepid, 2003 Chrysler Intrepid, and 2003 Chrysler Concorde. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the piston rings. (Refer to PISTON RINGS ).
  2. Before installing piston 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.
  3. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown in (Figure).
  4. Immerse the piston head and rings in clean engine oil, slide the ring compressor over the piston and tighten with the special wrench. Ensure position of rings does not change during this operation. 
    CAUTION: Ensure the hole in bearing half aligns with hole in connecting rod, as damage to engine may occur.
  5. Position bearing onto connecting rod. Ensure that hole in bearing half is aligned to hole in connecting rod. Lubricate bearing surface with clean engine oil.
  6. Install Special Tools 8189 Connecting Rod Guides into connecting rod (Figure).
  7. The pistons are marked on top with an arrow and with an "F" (Front) above the pin boss. These marks must be pointing toward the front of engine on both cylinder banks. The connecting rod oil hole squirt faces the major thrust (right) side of the block (Fig 1).
    Fig 1: Identifying Piston And Connecting Rod Positioning (Front View Of Engine)
    G02709601Courtesy of DAIMLERCHRYSLER CORP.
  8. 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 (Fig 2).
    CAUTION: Do Not interchange piston assemblies bank to bank, as engine damage may occur.
RENDER: 1.0x

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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.