Cylinders, Pistons And Piston Rings Inspection - Suzuki 2006 SX4 Service Manual

1D-52 Engine Mechanical:

Cylinders, Pistons and Piston Rings Inspection

Cylinder
Visual inspection
Inspect cylinder walls for scratches, roughness or ridges
which indicate excessive wear. If cylinder bore is very
rough or deeply scratched, or ridged, rebore cylinder and
use over size piston.
Cylinder bore diameter, taper and out-of-round
Using a cylinder gauge (1), measure cylinder bore in
thrust and axial directions at two positions ("a" and "b")
as shown in figure.
If any of the following conditions is noted, rebore
cylinder.
1) Cylinder bore dia. exceeds limit.
2) Difference of measurements at two positions
exceeds taper limit.
3) Difference between thrust and axial measurements
exceeds out-of-round limit.
Cylinder bore diameter
Standard: 78.000 – 78.014 mm (3.0709 – 3.0714
in.)
Limit: 78.050 mm (3.073 in.)
Cylinder taper and out-of-round
Limit: 0.10 mm (0.004 in.)
NOTE
If any one of four cylinders has to be rebored,
rebore all four to the same next oversize.
This is necessary for the sake of uniformity
and balance.
S6RW0D1406034
Piston
Visual inspection
Inspect piston for faults, cracks or other damages.
Damaged or faulty piston should be replaced.
Piston diameter
As indicated in figure, piston diameter should be
measured at a position 19.5 mm (0.77 in.) ("a") from
piston skirt end in the direction perpendicular to piston
pin.
Piston diameter specification
Standard size (used piston): 77.953 – 77.968 mm
(3.0690 – 3.0696 in.)
Standard size (new piston with coating): 77.963 –
77.990 mm (3.0694 – 3.0704 in.)
Oversize (0.50 mm (0.0196 in.)) (used piston): 78.453
– 78.468 mm (3.0887 – 3.0893 in.)
Oversize (0.50 mm (0.0196 in)) (new piston with
coating): 78.463 – 78.490 mm (3.0891 – 3.0901 in.)
"a": 50 mm (1.96 in.)
"b": 100 mm (3.94 in.)
I2RH0B140117-01
I2RH01140157-01