Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation: Installation
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.
- 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 arrow 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 arrow 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 AND CYLINDER HEADS REMOVAL AND INSTALLATION: ".
- Install oil pump to cylinder block referring to "OIL PUMP REMOVAL AND INSTALLATION ".
- Install valve lash adjusters and camshafts referring to "CAMSHAFTS AND VALVE LASH ADJUSTERS REMOVAL AND INSTALLATION ".
- Install RH bank 2nd timing chain referring to "RH (NO. 2) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER INSTALLATION ".
- Install 1st timing chain. Refer to "1ST TIMING CHAIN AND CHAIN TENSIONER INSTALLATION ".
- Install LH bank 2nd timing chain. Refer to "LH (NO. 1) BANK 2ND TIMING CHAIN AND CHAIN TENSIONER INSTALLATION ".
- Install timing chain cover. Refer to "TIMING CHAIN COVER REMOVAL AND INSTALLATION ".
- Install oil pan and pump strainer. Refer to "OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION ".
- Install cylinder head cover. Refer to "CYLINDER HEAD COVERS REMOVAL AND INSTALLATION ".
- Install exhaust manifold. Refer to "EXHAUST MANIFOLD REMOVAL AND INSTALLATION ".
- Install radiator outlet pipe, radiator, cooling fan and water hose.
Refer to "COOLING WATER PIPES OR HOSES REMOVAL AND INSTALLATION :", "RADIATOR REMOVAL AND INSTALLATION " and "COOLING FAN AND FAN CLUTCH REMOVAL AND INSTALLATION ".
- Install throttle body and intake manifold. Refer to "THROTTLE BODY AND INTAKE MANIFOLD INSTALLATION ".
- Adjust water pump drive belt tension. Refer to "COOLING FAN / GENERATOR BELT CHECK AND ADJUSTMENT ".
- Adjust power steering pump drive belt tension. Refer to "COOLING FAN / GENERATOR BELT CHECK AND ADJUSTMENT ".
- Adjust accelerator cable play and A/T throttle cable play. Refer to "Accelerator Cable Adjustment and A/T Throttle Cable Adjustment (for A/T Vehicle) ".
- 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 referring to appropriate maintenance for engine oil and filter change.
- Refill cooling system referring to "COOLING SYSTEM FLUSH AND REFILL ".
- Refill front differential housing with gear oil referring to "FRONT DIFFERENTIAL GEAR OIL INSPECTION AND CHANGE ", if necessary.
- Connect negative cable at battery.
- Check ignition timing and adjust as necessary referring to "IGNITION TIMING CHECK AND ADJUSTMENT ".
- Verify that there is no fuel leakage, water leakage, oil leakage and exhaust gas leakage at each connection.
- Check wheel alignment referring to "WHEEL ALIGNMENT SPECIFICATIONS ".