Toyota 13103-66040 Piston Sub-Assy, W/Pin

Prior to removing the piston and connecting rod assemblies, the cylinder head, oil pan, and oil pump must be taken off. First, use your fingernail to check for any ridge at the upper limit of ring travel, which is about 1/4-inch down from the top of each cylinder. If ridges are present due to carbon deposits or cylinder wear, they must be completely removed with a ridge reamer before attempting to remove the pistons to avoid breakage. Once the ridges are cleared, turn the engine upside-down with the crankshaft facing up. Before removing the connecting rods, check the endplay using feeler gauges, ensuring the play is eliminated. If the endplay exceeds the service limit, new connecting rods may be necessary. Check the connecting rods and caps for identification marks, and if they are not marked, use a center-punch to create indentations. Loosen the connecting rod cap nuts gradually until they can be removed by hand, then take off the number one connecting rod cap and bearing insert without dropping the 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 to apply pressure on the upper bearing surface. If resistance is encountered, ensure all ridge material has been removed. Repeat this process for the remaining cylinders. After removal, reassemble the connecting rod caps and bearing inserts in their respective rods and install the cap nuts finger tight to prevent damage to the bearing surfaces. It is important not to separate the pistons from the connecting rods.

Lubricate the piston and rings with clean engine oil, attach a piston ring compressor to the piston, and leave the skirt protruding about 1/4-inch to guide the piston into the cylinder. The rings must be compressed until they are flush with the piston.