Pistons, Piston Rings, Connecting Rods & Cylinders Removal & Installation: Installation
WARNING: This page is about a different car, the 2004 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.
- Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crank pins.NOTE: Do not apply oil between connecting rod and bearing or between bearing cap and bearing.
- Install guide hoses (1) over connecting rod bolts.
These guide hoses (1) protect crank pin and threads of rod bolt from damage during installation of connecting rod and piston assembly.
- When installing piston and connecting rod assembly into cylinder bore, point mark (1) on piston head to crankshaft pulley side (2).
- Install piston and connecting rod assembly into cylinder bore. Use special tool (Piston ring compressor) to compress rings. Guide connecting rod into place on crankshaft.
Using a hammer handle, tap piston head to install piston into bore. Hold ring compressor firmly against cylinder block until all piston rings have entered cylinder bore.
Special tool
(A): 09916-77310
- Install bearing cap
Point mark (1) on cap to crankshaft pulley side (2). Tighten cap nuts to specification.
Tightening torque
Connecting rod bearing cap nut (a): 45 N.m (4.5 kg-m, 32.5 lb-ft)
- Install cylinder heads to cylinder block referring to VALVES & CYLINDER HEADS REMOVAL & INSTALLATION .
- Install oil pump to cylinder block referring to OIL PUMP REMOVAL & INSTALLATION .
- Install valve lash adjusters and camshafts referring toCAMSHAFTS & VALVE LASH ADJUSTERS REMOVAL & INSTALLATION .
- Install RH bank 2nd timing chain referring to RH (NO. 2) BANK 2ND TIMING CHAIN & CHAIN TENSIONER INSTALLATION .
- Install 1st timing chain. Refer to 1ST TIMING CHAIN & CHAIN TENSIONER INSTALLATION .
- Install LH bank 2nd timing chain. Refer to LH (NO. 1) BANK 2ND TIMING CHAIN & CHAIN TENSIONER INSTALLATION .
- Install timing chain cover. Refer to TIMING CHAIN COVER REMOVAL & INSTALLATION .
- Install oil pan and pump strainer. Refer to OIL PAN & OIL PUMP STRAINER REMOVAL & INSTALLATION .
- Install cylinder head cover. Refer to CYLINDER HEAD COVERS REMOVAL & INSTALLATION .
- Install exhaust manifold. Refer to EXHAUST MANIFOLD REMOVAL & INSTALLATION .
- Install radiator outlet pipe, radiator, cooling fan and water hose.
Refer to COOLING WATER PIPES OR HOSES REMOVAL & INSTALLATION , RADIATOR REMOVAL & INSTALLATION and COOLING FAN & FAN CLUTCH REMOVAL & INSTALLATION .
- Install intake manifold with throttle body.
Refer to THROTTLE BODY & INTAKE MANIFOLD REMOVAL & INSTALLATION (H25 ENGINE) .
- Adjust water pump drive belt tension. Refer to COOLING FAN/GENERATOR BELT TENSION CHECK & ADJUSTMENT .
- Adjust power steering pump drive belt tension. Refer to P/S PUMP DRIVE BELT INSPECTION & ADJUSTMENT .
- Adjust accelerator cable play and A/T throttle cable play. Refer to ACCELERATOR CABLE ADJUSTMENT and A/T THROTTLE CABLE ADJUSTMENT (H25 ENGINE WITH A/T ONLY) .
- Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
- Refill engine with engine oil .
- Refill cooling system referring to COOLING SYSTEM FLUSH & REFILL .
- Refill front differential housing with gear oil if drained, referring to FRONT DIFFERENTIAL GEAR OIL INSPECTION & CHANGE .
- Connect negative cable at battery.
- Check ignition timing and adjust as necessary, referring to IGNITION TIMING CHECK & ADJUSTMENT .
- Verify that there is no fuel leakage, water leakage, oil leakage and exhaust gas leakage at each connection.
- Check wheel alignment referring to SPECIFICATIONS & PROCEDURES .