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Fitting Pistons

WARNING: This page is about a different car, the 1992 Suzuki Swift, 1992 Suzuki Sidekick, and 1992 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  under OVERHAUL. See CYLINDER BLOCK  table under ENGINE SPECIFICATIONS to determine if block must be rebored.
  2. Pistons are available in .0098" (.25 mm) and .0196" (.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. Piston diameter is determined by numerical mark ("1" or "2") stamped on piston crown. See Fig 1 .
  4. Cylinder bore diameter is determined by numerical mark ("1" or "2") stamped on cylinder block. Numerical marks on cylinder block, read left to right, indicate bore sizes of cylinders No. 1, 2, 3 and 4, respectively. See Fig 1 .
  5. When installing piston into cylinder, ensure piston numerical mark matches cylinder bore numerical mark to provide correct piston-to-cylinder clearance.
Fig 1: Matching Pistons To Cylinders
G81634Courtesy of SUZUKI OF AMERICA CORP.
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