Piston & Rod Assembly
WARNING: This page is about a different car, the 2003 Suzuki Grand Vitara and 2002 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.
- 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.
- 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. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS.
- 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.