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

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.

2 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") on its piston head. It represents outer diameter of piston.
2. There are also stamped numbers of 1 and 2 on the cylinder block as shown.
3. Stamped number on piston and cylinder block must correspond. That is, install number "2" stamped piston to cylinder which is stamped also number "2" and a number "1" piston to cylinder with number "1".
  Also, a letter A, B or C is stamped on piston head but ordinarily it is not necessary to distinguish each piston by this letter.
Piston-to-cylinder clearance (Piston)

Fig 1: Piston-To-Cylinder Clearance (Piston) Specifications Chart
Courtesy of SUZUKI OF AMERICA CORP.

Piston-to-cylinder clearance (Cylinder)

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

Piston-to-cylinder clearance

0.02 - 0.04 mm (0.0008 - 0.0015 in.)

Fig 3: Identifying Piston-To-Cylinder Clearance
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 (1) and connecting rod (3), 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 must face toward crankshaft pulley side.
Fig 4: Fitting Connecting Rod To Piston
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: Installing Circlip With Cut Part Facing
Courtesy of SUZUKI OF AMERICA CORP.
Install piston rings to piston:
- As indicated in the figure, 1st (1) and 2nd rings (2) have "RN" or "R" mark respectively. When installing these piston rings to piston, direct marked side of each ring toward top of 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 (3), install spacer first and then two rails.
Fig 6: Installing Piston Rings To Piston
Courtesy of SUZUKI OF AMERICA CORP.
After installing 3 rings (1st, 2nd and oil rings), distribute their end gaps as shown in the figure.

Fig 7: Distributing Rings End Gap
Courtesy of SUZUKI OF AMERICA CORP.