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Home >> Suzuki >> 2001 >> XL-7 Limited >> Repair and Diagnosis >> External Pages >> Different car >> Section 131 (2.0L 4-Cylinder) >> Repair Instructions >> Pistons, Piston Rings, Connecting Rods & Cylinders Removal and Installation >> Installation

Pistons, Piston Rings, Connecting Rods & Cylinders Removal and Installation: Installation

WARNING: This page is about a different car, the 2003 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.
  1. Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crankpins.
    NOTE: Do not apply oil between connecting rod and bearing or between bearing cap and bearing.
  2. 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.
    Fig 1: Identifying Protective Guide Hose (For Rod Bolts)
    G01351948Courtesy of SUZUKI OF AMERICA CORP.
  3. When installing piston and connecting rod assembly into cylinder bore, point arrow mark (3) on piston head to crankshaft pulley side (1).
    Fig 2: Identifying Piston Installation Position
    G01351949Courtesy of SUZUKI OF AMERICA CORP.
  4. 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 

    1. (A):  09916-77310
    Fig 3: Installing Piston & Connecting Rod Assembly
    G01351950Courtesy of SUZUKI OF AMERICA CORP.
  5. Install bearing cap:

    Point arrow mark (1) on cap to crankshaft pulley side. Tighten cap nuts to specification.

    Tightening torque 

    1. Connecting rod bearing cap nut (a):  45 N-m (4.5 kg-m, 33.0 lb-ft)
    Fig 4: Identifying Connecting Rod Bearing Cap Installation Position & Connecting Rod Bearing Cap Nut
    G01351951Courtesy of SUZUKI OF AMERICA CORP.
  6. Install oil pump. See OIL PUMP REMOVAL AND INSTALLATION .
  7. Install cylinder head with intake manifold, exhaust manifold and water outlet pipe. See VALVES & CYLINDER HEAD REMOVAL .
  8. Install exhaust manifold stiffener (if equipped) and connect exhaust No. 1 pipe to exhaust manifold. See EXHAUST MANIFOLD REMOVAL & INSTALLATION .
  9. Install camshafts and valve lash adjusters. See CAMSHAFT, VALVE LASH ADJUSTERS REMOVAL & INSTALLATION .
  10. Install 1st and 2nd timing chains. See 1ST TIMING CHAIN & CHAIN TENSIONER INSTALLATION  and 2ND TIMING CHAIN & CHAIN TENSIONER INSTALLATION .
  11. Install timing chain cover. See TIMING CHAIN COVER REMOVAL & INSTALLATION .
  12. Install oil pan and oil pump stainer. See OIL PAN, OIL PUMP STRAINER REMOVAL & INSTALLATION .
  13. Install cylinder head cover. See CYLINDER HEAD COVER REMOVAL & INSTALLATION .
  14. Install intake manifold rear stiffener and connect water pipe to intake manifold.
  15. Connect each hoses and electric lead wires.
  16. Install air cleaner outlet hose.
  17. Install strut tower bar.
  18. Adjust cooling belt tension. See COOLING FAN BELT TENSION CHECK & ADJUSTMENT .
  19. Adjust accelerator cable play and A/T throttle cable play (for vehicle with A/T). SeeACCELERATOR CABLE ADJUSTMENT  and A/T THROTTLE CABLE ADJUSTMENT (FOR A/T VEHICLE) .
  20. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
  21. Refill engine with engine oil.
  22. Refill cooling system. See COOLING SYSTEM FLUSH & REFILL .
  23. Refill front differential housing with gear oil. See FRONT DIFFERENTIAL GEAR OIL INSPECTION & CHANGE .
  24. Refill power steering system with specified fluid.
  25. Connect negative cable at battery.
  26. Verify that there is no fuel leakage, coolant leakage, oil leakage and exhaust gas leakage at each connection.
  27. Check ignition timing and adjust as necessary. See VITARA (2.0L), GRAND VITARA (2.5L) & XL-7 (2.7) .
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