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Home >> Suzuki >> 2007 >> Swift + >> Repair and Diagnosis >> Engine Mechanical >> Engine Mechanical - 1.6L >> Repair Instructions >> Piston, Connecting Rod, and Bearing Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: Pressing Out Piston Pin
    GM1241706Courtesy of GENERAL MOTORS CORP.
  1. Align the notch on the piston and the connecting rod so that the proper sides will be facing the front of the engine.
  2. Install the piston pin guide through the piston and the connecting rod.
  3. Coat the piston pin with clean oil.
  4. Install the piston pin into the opposite side of the piston.
  5. Install the piston pin into the piston and connecting rod assembly using J 24086-B  (1).
  6. Select a set of new piston rings.
  7. Measure the piston ring gap using a feeler gage. Refer to Engine Mechanical Specifications .
  8. Increase the piston ring gap by carefully filing off excess material if the piston ring gap is below specifications.
    9. Fig 2: Measuring Piston Ring Side Clearance
    GM1289598Courtesy of GENERAL MOTORS CORP.
  9. Measure the piston ring side clearance using a feeler gage. Refer to Engine Mechanical Specifications .
  10. If the piston ring is too thick, try another piston ring.
  11. If no piston ring can be found that fits to specifications, the piston ring may be ground to size with emery paper placed on a sheet of glass.
    12. Fig 3: Installing Piston Oil Rings, Second Compression Ring, And Top Compression Ring
    GM1289611Courtesy of GENERAL MOTORS CORP.
  12. Install a piston oil ring, the expander, then the second piston oil ring to the bottom ring groove of the piston.
  13. Install the second compression ring to the middle ring groove of the piston.
  14. Install the top compression ring to the top ring groove of the piston.
    15. Fig 4: View Of Piston Oil Rings, Oil Ring Rail Gaps, Second Compression Ring, Top Compression Ring And Piston Top Notch
    GM1289625Courtesy of GENERAL MOTORS CORP.
  15. Use a piston ring expander to install the piston rings. Do not expand the piston rings beyond the expansion necessary for installation.
  16. Stagger the piston oil rings (3), the oil ring rail gaps (1), the second compression ring (4), and the top compression ring (3) in relation to the notch on the top of the piston (2).
    17. Fig 5: Installing Piston Using Ring Compressor And Wood Handle
    GM1289640Courtesy of GENERAL MOTORS CORP.
  17. Lubricate the cylinder wall and the piston rings with clean engine oil.
  18. Install the piston using a ring compressor and a wood handle. Guide the lower connecting rod end to prevent damaging the crankshaft journal.
  19. Install the connecting rod cap and bearings. Refer to Crankshaft and Bearings Cleaning and Inspection .
    20. Fig 6: Tightening Connecting Rod Bearing Cap Bolts
    GM1289653Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
  20. Install the connecting rod cap bolts.

    Tighten:  Tighten the connecting rod bearing cap bolts to 25 N.m (18 lb ft). Using the J 45059  , tighten the bolts one turn of 30 degrees plus one turn of 15 degrees.

    21. Fig 7: View Of Oil Suction Pipe And Bolts
    GM1291382Courtesy of GENERAL MOTORS CORP.
  21. Install the oil suction pipe.
  22. Install the oil suction pipe bolts.

    Tighten:  Tighten the oil suction pipe bolts to 10 N.m (89 lb in).

  23. Install the oil pan. Refer to Oil Pan Replacement .
  24. Install the cylinder head with the intake manifold and the exhaust manifold attached. Refer to Cylinder Head Replacement .
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