LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Suzuki >> 1999 >> Grand Vitara JS, Standard >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 2.5L V6 >> Overhaul >> Cylinder Block Assembly >> Piston & Rod Assembly
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Piston & Rod Assembly

  1. Remove cylinder heads. See CYLINDER HEAD  under REMOVAL & INSTALLATION. Ensure pistons, connecting rods and rod caps are marked for reassembly reference. Remove carbon from top of cylinder bores. Remove connecting rod cap bolts and rod caps. Install protective hose over connecting rod bolts. Remove piston and connecting rod assembly through top of cylinder block. Mark cylinder number on piston crown. Remove rings from piston.
  2. Using suitable tool, remove piston pin circlip, and push piston pin out. Check piston pin-to-bore fit. Pin should press in piston smoothly by hand at room temperature. Measure diameters of piston, piston pin and pin bore. PISTONS, PINS & RINGS  table under ENGINE SPECIFICATIONS.
  3. When assembling, apply engine oil to outside of pin and to piston pin bore. Install piston pin circlip to one end of piston. Insert pin from other side of piston through rod small end until it contacts circlip. Install remaining circlip into piston. Position circlips with opening parallel to piston top and facing oil hole in connecting rod.
scientia non olet · About LEMON Manuals