Cylinders, Pistons and Piston Rings Inspection: Pistons

WARNING: This page is about a different car, the 2004 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Inspect piston for faults, cracks or other damages.
Damaged or faulty piston should be replaced.
Piston diameter:
As indicated in the figure, piston diameter should be measured at a position "a": 26.5 mm (1.04 in.) from piston skirt end in the direction perpendicular to piston pin.

Piston diameter

Standard: 83.970 - 83.990 mm (3.3059 - 3.3066 in.)

Oversize (0.50 mm (0.0197 in.)): 84.470 - 84.490 mm (3.3256 - 3.3263 in.)

Fig 1: Measuring Piston Diameter
Courtesy of SUZUKI OF AMERICA CORP.
Piston clearance:
Measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification. If it is out of specification, rebore cylinder and use oversize piston.

Piston clearance

0.02 - 0.04 mm (0.0008 - 0.0015 in.)

NOTE: Cylinder bore diameters used here are measured in thrust direction at two positions.

Fig 2: Measuring Cylinder Bore Diameter & Piston Diameter
Courtesy of SUZUKI OF AMERICA CORP.
Ring groove clearance:
Before checking, piston grooves must be clean, dry and free of carbon.

Fit new piston ring (1) into piston groove, and measure clearance between ring and ring land by using thickness gauge (2). If clearance is out of specification, replace piston.

Ring groove clearance

Top: 0.03 - 0.07 mm (0.0012 - 0.0027 in.)

2nd: 0.02 - 0.06 mm (0.0008 - 0.0023 in.)

Fig 3: Fitting Piston Ring Into Piston Groove
Courtesy of SUZUKI OF AMERICA CORP.