Dodge Durango

 Service Manual

Engine » Removal and installation
Piston and connecting rod

REMOVAL

(1) Disconnect negative cable from battery.

(2) Remove the following components: (Refer to procedures in this section)

•  Oil pan and gasket/windage tray.
•  Cylinder head covers.
•  Timing chain cover.
•  Cylinder head(s).

(3) If necessary, remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so the each connecting rod is centered in cylinder bore.

CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly. (4) Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool (Fig.

111).

CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur. (5) Remove connecting rod cap. Install Special Tool 8507 Connecting Rod Guides into the connecting rod being removed. Remove piston from cylinder bore.

Repeat this procedure for each piston being removed.

Fig. 111 Identify Connecting Rod to Cylinder Position-Typical

CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur (6) Immediately after piston and connecting rod removal, install bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.

(7) Carefully remove piston rings from piston(s), starting from the top ring down.

PISTON RINGS-INSTALLATION

(1) The No. 1 and No. 2 piston rings have a different cross section. Ensure No. 2 ring is installed with manufacturers I.D. mark (Dot) facing up, towards top of the piston.

NOTE: Piston rings are installed in the following order:

•  Oil ring expander.
•  Upper oil ring side rail.
•  Lower oil ring side rail.
•  No. 2 Intermediate piston ring.
•  No. 1 Upper piston ring.

(2) Install the oil ring expander.

(3) Install upper side rail (Fig. 112) by placing one end between the piston ring groove and the expander ring. Hold end firmly and press down the portion to be installed until side rail is in position. Repeat this step for the lower side rail.

(4) Install No. 2 intermediate piston ring using a piston ring installer (Fig. 113).

(5) Install No. 1 upper piston ring using a piston ring installer (Fig. 113).

(6) Position piston ring end gaps as shown in (Fig.

114). It is important that expander ring gap is at least 45 from the side rail gaps, but not on the piston pin center or on the thrust direction.

INSTALLATION

(1) Before installing piston and connecting rod assemblies in to the bore, ensure all rings are in position shown in (Fig. 114).

Fig. 112 Side Rail-Installation

1 - SIDE RAIL END

Fig. 113 Upper and Intermediate Rings-Installation

(2) Immerse the piston head and rings in clean engine oil. Position a ring compressor over the piston and rings. Tighten ring compressor. Ensure position of rings do not change during this operation.

(3) Position bearing onto connecting rod. Ensure that hole in bearing shell aligns with hole in connecting rod. Lubricate bearing surface with clean engine oil.

(4) Install Special Tool 8507 Connecting Rod Guides into connecting rod bolt threads (Fig. 115).

(5) The pistons are marked on the piston pin bore surface with an raised "F" indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks. The connecting rod oil slinger slot faces the front of the engine (Fig. 116).

(6) Wipe cylinder bore clean and lubricate with engine oil.

Fig. 114 Piston Ring End Gap Position

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. 115 Piston and Connecting Rod-Installation

1 - "F" TOWARD FRONT OF ENGINE

2 - OIL SLINGER SLOT

3 - RING COMPRESSOR

4 - SPECIAL TOOL 8507

Fig. 116 Piston and Connecting Rod Positioning

1 - MAJOR THRUST SIDE OF PISTON

2 - OIL SLINGER SLOT

(7) Rotate crankshaft until connecting rod journal is on the center of cylinder bore. Insert rod and piston into cylinder bore and carefully position connecting rod guides over crankshaft journal.

(8) Tap piston down in cylinder bore using a hammer handle. While at the same time, guide connecting rod into position on rod journal.

CAUTION: Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed. (9) Lubricate rod bolts and bearing surfaces with engine oil. Install connecting rod cap and bearing.

Tighten bolts to 27 N*m (20 ft. lbs.) plus 90.

(10) Install the following components: (Refer to procedures in this section)

•  Cylinder head(s).
•  Timing chain and cover.
•  Cylinder head covers.
•  Oil pan and gasket/windage tray.

(11) Fill crankcase with proper engine oil to correct level.

(12) Connect negative cable to battery.

Engine mounts-left and right

Engine mount-rear

Structural cover

Engine assembly

Intake manifold

Exhaust manifolds

Cylinder head cover

Rocker arms

Cylinder heads

Valve springs and seals

Hydraulic lash adjuster

Crankshaft damper

Timing chain cover

Timing chain and sprockets

Idler shaft-timing drive

Camshafts-in vehicle

Crankshaft main bearings

Oil pan 4x2 vehicle

Oil pan 4x4 vehicle

Piston and connecting rod

Crankshaft

Flexplate

Oil pump

Engine oil pressure sending unit

Crankshaft oil seal-front

Crankshaft oil seal-rear

Engine core plugs