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HOMESERVICE MANUALSCHRYSLER2004PT CRUISER TOURING, 2.4 B, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 102 (3.5L)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, 2003 Chrysler Concorde, and 2003 Chrysler 300M. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the piston rings. (Refer to INSTALLATION ).
    NOTE: The connecting rod bearing cap bolts must be examined before reuse. If the threads are necked down, the bolts must be replaced.
  2. Check connecting rod bolts for necking by holding a scale or straight edge against the threads. If all threads do not contact the scale, the bolt must be replaced (Fig 1).
    Fig 1: Checking For Stretched Bolts
    G02709791Courtesy of DAIMLERCHRYSLER CORP.
  3. 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 (Fig 2).
    Fig 2: Identifying Piston Ring End Gap Position
    G02709792Courtesy of DAIMLERCHRYSLER CORP.
  4. Immerse the piston head and rings in clean engine oil, slide the ring compressor over the piston and tighten with the special wrench (Fig 3). Ensure position of rings does not change during this operation. 
    Fig 3: Installing Piston
    G02709793Courtesy of DAIMLERCHRYSLER CORP.
  5. Install connecting rod bolt protectors on rod bolts (Figure).
  6. 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.
    CAUTION: Do Not interchange piston assemblies cylinder-to-cylinder or bank-to-bank.
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.