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Piston & Rod Assembly

  1. Remove cylinder head. See CYLINDER HEAD  under REMOVAL & INSTALLATION. Remove oil dipstick guide, oil pan and screen. See OIL PAN  under REMOVAL & INSTALLATION.
  2. Ensure pistons, connecting rods and rod caps are marked for reassembly reference. Remove carbon from top of cylinder bores. Remove connecting rod caps. Install protective hose over connecting rod bolts.
  3. Remove connecting rod and piston assembly through top of cylinder block. Mark cylinder number on piston crown. Remove piston rings.
  4. Use Piston Pin Remover/Installer (09910-38211).
  5. Check piston pin-to-bore fit. Pin should press in piston smoothly by hand at room temperature. When assembling, apply engine oil to outside of pin and to piston pin bore.
  6. Position piston upward. Align piston, pin and rod with Piston Pin Remover/Installer (09910-38211). Press pin into piston and rod using a hydraulic press. See Fig 1.
Fig 1: Installing Piston Pin
G96D18567Courtesy of SUZUKI OF AMERICA CORP.
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