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

4) Install piston pin to piston (1) and connecting rod (3):
After applying engine oil to piston pin, piston pin
holes in piston and inner surface of connecting rod
small end, 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) comes on intake side.
• Circlip (5) should be installed so that
circlip end gap comes within such range
as indicated by arrow.
1
3
4
"a": 90°
2. Front mark
5) Install piston rings to piston:
• As indicated in figure at the left, 1st and 2nd rings
have "R" 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.
• When installing oil ring (3), install spacer first and
then two rails.
2
5
"a"
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4. Oil hole
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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.)
Engine Mechanical: 1D-48
I5JB0A142053-01
S6RW0C1406036