Pistons, Piston Rings, Connecting Rods And Cylinders Inspection And Cleaning - Suzuki Grand Vitara 2011 Manual

1D-112 Engine Mechanical: For J20 Engine
4) Install piston pin to piston (1) and connecting rod (3):
After applying engine oil to piston pin and piston pin
holes in piston and connecting rod, fit connecting rod
to piston as shown in figure and insert piston pin to
piston and connecting rod, and install piston pin
circlips.
NOTE
Oil hole (4) come on intake side.
1
3
4
2. Front mark
NOTE
Circlip (4) should be installed so that circlip
end gap comes within such range as
indicated by arrow.
5
1. Piston
2. Front mark
5) Install piston rings to piston:
• As indicated in figure at the left, 1st and 2nd rings
have "TOP" mark respectively. When installing
these piston rings to piston, direct marked side of
each 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
figure.
2
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4. Oil hole
4
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3. Connecting rod
5. Oil hole
• When installing oil ring (3), install spacer first and
then two rails.
6) After installing three rings (1st, 2nd and oil rings),
distribute their end gaps as shown in figure.
1. Front mark
2. 1st ring end gap
3. 2nd ring end gap and oil ring spacer gap
4. Oil ring upper rail gap
5. Oil ring lower rail gap
6. Intake side
7. Exhaust side
Pistons, Piston Rings, Connecting Rods and
Cylinders Inspection and Cleaning
Inspection
Cylinder
• 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.
• Using a cylinder gauge, measure cylinder bore in
thrust and axial directions at two positions as shown in
figure.
If any of following conditions is noted, rebore cylinder.
1) Cylinder bore diameter 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: 84.000 – 84.020 mm (3.3070 – 3.3078
in.)
Limit: 84.050 mm (3.3090 in.)
Taper and out-of-round
Limit: 0.10 mm (0.004 in.)
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