Toyota 13101-62060-03 Piston Sub-Assy, W/Pin

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Prior to removing the piston and connecting rod assemblies, the cylinder head(s), oil pan, and oil pump pick-up at the upper limit of ring travel (approximately 1/4-inch down from the top of each cylinder) must be removed. If carbon deposits or cylinder wear have created ridges, these must be completely eliminated using a special tool, specifically a ridge reamer, before the pistons are removed to avoid piston damage. After the ridges are removed, turn the engine upside-down with the crankshaft facing up. Before disconnecting the connecting rods, check the endplay with feeler gauges by sliding them between the first connecting rod and the crankshaft throw until the play is eliminated; the endplay corresponds to the thickness of the feeler gauge(s). If the endplay exceeds the specified service limit, new connecting rods will be necessary. If new rods or a new crankshaft are installed, the endplay may fall below the service limit, requiring machining of the rods to restore it. Check the connecting rods and caps for identification marks; if they are not clearly marked, use a small center punch to create indentations on each rod and cap to indicate their associated cylinder. Loosen each connecting rod cap nut by 1/2-turn until they can be removed by hand, then take off the number one connecting rod cap and bearing insert without dropping the bearing insert. To protect the crankshaft journal and cylinder wall during piston removal, slip a short length of plastic or rubber hose over each connecting rod cap bolt. Remove the bearing insert and push the connecting rod/piston assembly out through the top of the engine using a wooden hammer handle on the upper bearing surface in the connecting rod; if resistance is encountered, ensure all ridge material has been removed from the cylinder. Repeat this process for the remaining cylinders, turning the crankshaft as needed to align the rod with the cylinder bore. After removal, reassemble the connecting rod caps and bearing inserts in their respective rods and install the cap nuts finger tight to prevent accidental damage to the bearing surfaces. Avoid separating the pistons from the connecting rods.

The connecting rod endplay must be checked and compared to ensure it is correct. If new rods or a new crankshaft were installed, the endplay may need adjustment.

All traces of carbon should be scraped from the top of the piston. A hand-held wire brush or fine emery cloth can be used after the majority of the deposits have been scraped away. It is crucial not to use a wire brush mounted in a drill motor, as the piston material is soft and may be eroded.

A piston ring installation tool should be used to carefully remove the rings from the pistons, ensuring not to nick or gouge the pistons in the process.

Cut a piece of Plastigage slightly shorter than the width of the connecting rod bearing, lay it on the number one connecting rod journal, and then install the rod cap. After tightening, remove the cap and compare the width of the crushed Plastigage to the scale on the envelope.

No, do not separate the pistons from the connecting rods. For additional information, refer to Section 18.

Clean the back side of the other bearing insert and install it in the rod cap, ensuring the tab fits into the recess and without applying any lubricant. The mating surfaces must be perfectly clean and oil-free.

Each piston should be carefully inspected for cracks around the skirt, at the pin bosses, and at the ring lands.

Check the connecting rods and caps for identification marks. If they aren't plainly marked, use a small center punch to make the appropriate number of indentations on each rod and cap, indicating which cylinder they are associated with.