Pistons, Piston Rings, Connecting Rods And Cylinders Disassembly And Assembly - Suzuki Grand Vitara 2011 Manual

1D-44 Engine Mechanical: For M16A Engine with VVT
Pistons, Piston Rings, Connecting Rods and
Cylinders Disassembly and Assembly
Disassembly
1) Using piston ring expander, remove two
compression rings (Top and 2nd) and oil ring from
piston.
2) Remove piston pin from connecting rod as follows.
a) Ease out piston pin circlips (1), as shown.
b) Force piston pin out.
Assembly
1) Decarbonize piston head and ring grooves using a
suitable tool.
2) Install piston pin to piston (1) and connecting rod (2):
a) After applying engine oil to piston pin and piston
pin holes in piston and connecting rod.
b) Fit connecting rod as shown in the figure.
c) Insert piston pin to piston and connecting rod.
d) Install piston pin circlips (3).
NOTE
Circlip should be installed with its cut part
S6JB0A1416030
facing as shown in the figure. Install so that
circlip end gap comes within such range as
indicated by arrow.
3) Install piston rings to piston:
• As indicated in the figure, 1st and 2nd rings have
"T" mark (4) respectively. When installing these
piston rings to piston, direct marked side of each
I2RH0B140113-01
ring toward top of piston.
• 1st ring (1) differs from 2nd ring (2) 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.
I2RH0B140114-01
4) After installing three rings (1st, 2nd and oil rings),
distribute their end gaps as shown in the figure.
1. Arrow mark
2. 1st ring end gap
3. 2nd ring end gap and oil ring spacer gap
I2RH0B140115-01
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4. Oil ring upper rail gap
5. Oil ring lower rail gap