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Fitting Pistons

WARNING: This page is about a different car, the 1991 Suzuki Swift, 1991 Suzuki Sidekick, and 1991 Suzuki Samurai. However, it is still accessible from the selected car via links, so may be relevant.
  1. Check cylinder bore for damage, wear and taper. See CYLINDER BLOCK under CYLINDER BLOCK ASSEMBLY OVERHAUL. See CYLINDER BLOCK  table under ENGINE SPECIFICATIONS to determine if block must be rebored.
  2. Pistons are available in .010" (.25 mm) and .020" (.50 mm) oversizes. Check outside diameter of piston. On 1.6L engine, measure at a point .63" (16.0 mm) from bottom of skirt and at 90 degrees to pin bore. On 1.3L engine, measure at a point .59" (15.0 mm) from bottom of skirt and at 90 degrees to pin bore.
  3. On all models, standard pistons are available in 2 sizes to ensure correct piston-to-cylinder clearance. Each standard piston has a number "1" or number "2" stamped on piston crown. See Fig 1 .
  4. The cylinder block is stamped with 4 numbers, either number "1" or number "2". The first number stamped on cylinder block indicates bore size of No. 1 cylinder. Second number indicates bore size of No. 2 cylinder. Third number indicates bore size of No. 3 cylinder. Fourth number indicates bore size of No. 4 cylinder.
  5. Install piston stamped number "1" into cylinder stamped number "1". Use a piston stamped number "2" in a cylinder stamped number "2".
Fig 1: Matching Pistons to Cylinders
G81634Courtesy of SUZUKI OF AMERICA CORP.
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