Pistons, Piston Rings, Connecting Rods, Cylinders Disassembly & Assembly: Assembly

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.

Two sizes of piston are available as standard size spare part so as to ensure proper piston-to-cylinder clearance.
When installing a standard size piston, make sure to match piston with cylinder as follows.
1. Each piston has stamped number 1 or 2 as shown. It represents outer diameter of piston.
2. There are also painted color of red or blue on the cylinder block (2) as shown. It represent inner diameter of cylinder.
  
  Fig 1: Identifying Piston Diameter Size Mark Location & Cylinder Size Mark Locations
  Courtesy of SUZUKI OF AMERICA CORP.
3. Stamped number on piston and painted mark on cylinder block should correspond. That is, install number 2 stamped piston to cylinder which is identified with mark blue and a number 1 piston to cylinder with mark red. Also, a letter A, B or C is stamped on piston head but ordinarily it is not necessary to discriminate each piston by this letter.
Piston-to-cylinder clearance

Fig 2: Piston-To-Cylinder Clearance Chart
Courtesy of SUZUKI OF AMERICA CORP.

Fig 3: Identifying Piston Code Number & Cylinder Color Code
Courtesy of SUZUKI OF AMERICA CORP.
Install piston pin to piston and connecting rod:
After applying engine oil to piston pin and piston pin holes in piston and connecting rod, fit connecting rod to piston as shown in the figure and insert piston pin to piston and connecting rod, and install piston pin circlips.
NOTE:
- "86F" mark on connecting rod should come on crankshaft pulley side.
  
  Fig 4: Identifying Piston Arrow Location & "86F" Mark On Connecting Rod
  Courtesy of SUZUKI OF AMERICA CORP.
- Install circlip with its cut part facing as shown in the figure.
- Install so that circlip end gap comes with such range as indicated by arrow "A".
Fig 5: Identifying Piston Circlip Installation Position, Piston Direction Arrow & Connecting Rod Oil Hole
Courtesy of SUZUKI OF AMERICA CORP.
Install piston rings to piston:
- As indicated in the figure, 1st and 2nd rings have "RN" or "R" mark respectively. When installing these piston.
- 1st rings differs from 2nd ring in thickness shape and color of surface contacting cylinder wall.
  Distinguish 1st ring from 2nd ring by referring to the figure.
- When installing oil ring, install spacer first and then two rails.
Fig 6: Locating Piston Ring Deactivation Letters & Piston Ring Installation Positions
Courtesy of SUZUKI OF AMERICA CORP.
After installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in the figure.

Fig 7: Identifying Piston Ring End Gap Positions
Courtesy of SUZUKI OF AMERICA CORP.