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Piston & Rod Assembly

WARNING: This page is about a different car, the 2002 Lexus LS 430. However, it is still accessible from the selected car via links, so may be relevant.
  1. Ensure connecting rod and connecting rod cap are marked with matching cylinder number for reassembly reference before removal. Using a ridge reamer, remove ring ridge in cylinder bores before removing pistons (if necessary). Using a dial indicator, check connecting rod thrust (side) clearance before removal. If thrust clearance exceeds specification, replace connecting rod assembly and/or crankshaft. See CONNECTING RODS  table under ENGINE SPECIFICATIONS.
    NOTE: Top of right piston contains 2 cavities for front mark, and left piston contains one cavity for front mark. Pistons are also marked "R" for right side and "L" for left side on piston boss. Connecting rod caps have an outside mark that should face toward crankshaft on installation. See Fig 1. Piston must be installed with front cavity marks properly positioned in relation to outside mark on connecting rod cap. Reference to right and left indicates sides as viewed from rear of engine (drive plate end).
    Fig 1: Identifying Piston & Connecting Rod Cap Front Marks
    G00050516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Remove connecting rod cap. Using Plastigage, check rod bearing oil clearance, with rod cap bolts tightened to specification. Remove rod cap and Plastigage and measure thickness of Plastigage to determine oil clearance. If clearance is not within specification, replace rod bearings and/or crankshaft. Remove piston and connecting rod assembly from cylinder block. Keep connecting rod, bearings and rod cap together.
  3. Using a ring expander, remove the 2 top compression rings, remove oil rings by hand. Using a small screwdriver, remove the 2 piston pin retaining rings from piston. Submerge piston and rod assembly in water and gradually heat to 140°F (60°C). Using a plastic mallet and brass bar, lightly tap piston pin out and remove connecting rod from piston.
  4. Ensure piston pin diameter is within specification. See PISTONS, PINS & RINGS  table under ENGINE SPECIFICATIONS.
  5. Ensure connecting rod piston pin bushing bore diameter, crankpin bore diameter, and rod bend and twist are within specification. See CONNECTING RODS  table under ENGINE SPECIFICATIONS.
  6. Using a press and appropriate driver, bushing in connecting rod can be replaced if bore diameter is not within specification. Ensure bushing oil hole aligns with connecting rod oil hole during installation. Hone bushing to obtain correct piston pin-to-rod clearance.
  7. To reassemble, install NEW piston pin retaining ring in piston. Install piston on connecting rod so front mark on piston is properly positioned with outside mark on connecting rod cap. See Fig 1. Heat piston to 140°F (60°C) in water. Coat piston pin with engine oil. Install piston pin through piston and connecting rod bushing. Install remaining NEW piston pin retaining ring in piston.
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