PISTON AND CONNECTING ROD
ENGINE OVERHAUL <4G63-Turbo>
11D-57
NOTE: The piston size mark is located on the
piston top surface.
2. Measure the following dimensions:
A: Piston pin insertion hole length
B: Distance between piston bosses
C: Piston pin length
D: Connecting rod small end width
3. Obtain dimension L from the measurements using
the following formula.
L = [(A-C) − (B-D)] ÷ 2
4. Insert the tool element, Push rod, into the piston
pin and attach the element, Guide A, to the push
rod end.
5. Assemble the connecting rod with the piston with
their front marks facing in the same direction.
6. Apply engine oil to the outside surface of the
piston pin.
7. Insert the assembly of piston pin, Push rod, and
Guide A (put together in step 4.) into the piston
holes from the front mark side.
8. Screw the tool element, Guide B, into the tool
element, Guide A until the gap between both the
elements is equal to the dimension L (obtained in
step 3.) plus 3 mm.
9. Place the piston and connecting rod assembly
onto the element, Piston setting base, with the
front marks facing up.
10.Install the piston pin using a press. If the required
press force is less than the standard value,
replace the piston and piston pin assembly or the
connecting rod, or both.
Standard value: 7,350 − 17,100 N
Cylinder bore size mark Piston size mark
IA
II No mark
III C
AK202784
Connecting rod
Piston
Piston pin
D
C
B
A
AD
AK301480
3 mm + L
Guide A
Guide B
AC
AK305971
P
AC
P
Push rod
Front mark
Front mark
Base
Guide A
Guide B
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