Suzuki 2000 Grand Vitara SQ625 Service Manual page 500

Cylinder Block
Distortion of gasketed surface
D Using straightedge and thickness gauge, check gasketed sur-
face for distortion and, if flatness exceeds its limit, correct it.
Flatness Limit: 0.06 mm (0.0024 in.)
Honing or reboring cylinders
1) When any cylinder needs reboring, all other cylinders must also
be rebored at the same time.
2) Select oversized piston according to amount of cylinder wear.
3) Using micrometer, measure piston diameter.
4) Calculate cylinder bore diameter to be rebored as follows.
D = A + B – C
D: Cylinder bore diameter to be rebored.
A: Piston diameter as measured.
B: Piston clearance = 0.02 – 0.04 mm
C: Allowance for honing = 0.02 mm
1. 26.5mm (1.04 in.)
5) Rebore and hone cylinder to calculated dimension.
NOTE:
Before reboring, install lower crankcase and tighten to
specification to avoid distortion of bearing bores.
6) Measure piston clearance after honing.
Check valve
Inspect check valve for clogging and ball for being stuck.
ENGINE MECHANICAL (J20 ENGINE) 6A4-81
Size Piston diameter
STD 83.970 – 83.990 mm (3.3059 – 3.3066 in.)
O/S 0.25 84.220 – 84.240 mm (3.3157 – 3.3165 in.)
O/S 0.50 84.470 – 84.490 mm (3.3256 – 3.3263 in.)
Piston clearance = (0.0008 – 0.0015 in.)
Allowance for honing = (0.0008 in.)