Piston, Piston Ring and Connecting Rod Disassembly and Reassembly: Reassembly

Reference: PISTON AND PISTON RING INSPECTION 

Reference: PISTON PINS AND CONNECTING RODS INSPECTION 

Reference: CRANK PIN AND CONNECTING ROD BEARINGS INSPECTION 

1. Remove carbon from piston head and ring grooves using suitable tool.
2. Install piston pin to piston (1) and connecting rod (2) as follows.
   1. Apply engine oil to piston pin and piston pin holes in piston and connecting rod.
   2. Fit connecting rod as shown in figure.
      NOTE: Be sure to position front mark (4) on piston and match mark (5) of connecting rod (2) at specified position as shown in figure.
   3. Insert piston pin to piston and connecting rod.
   4. Install new piston pin circlips (3).
      NOTE: Install circlip so that its end gap comes within the range indicated by arrow (6).
      Fig 1: Identifying Piston Pin Circlips Position

      Courtesy of SUZUKI OF AMERICA CORP.
3. Install piston rings to piston noting the following.
   • As indicated in figure, 1st and 2nd rings have direct discrimination mark (1) respectively. When installing these piston rings to piston, direct discrimination mark side of each ring toward top of piston.
   • 1st ring (2) differs from 2nd ring (3) in thickness, shape and color of surface contacting cylinder wall.

     Distinguish 1st ring from 2nd ring by referring to the figure.

   • When installing oil ring (4), install spacer (5) first and then two rails.
     Fig 2: Identifying Piston Rings Position

     Courtesy of SUZUKI OF AMERICA CORP.
4. After installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in figure.
   Fig 3: Identifying Oil Rings Gap

   Courtesy of SUZUKI OF AMERICA CORP.