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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.
    NOTE: On some 1.3L engines, pistons may be retained by circlips; others may be press fit.
  4. Use Piston Pin Remover/Installer (09910-38211) on 1.3L engine with press fit piston pins. On 1.6L engines (and some 1.3L engines), remove circlips, and push piston pin out by hand.
  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) for press fit 1.3L pistons. Press pin into piston and rod using a hydraulic press. See Fig 1. On 1.6L engines (and some 1.3L engines), install circlips and piston pin. Install circlips with opening facing either up or down.
Fig 1: Installing Piston Pin (1.3L - Press Fit)
G96D18567Courtesy of SUZUKI OF AMERICA CORP.
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