Piston, Piston Ring and Connecting Rod Removal and Installation: Installation

Reference: PISTON, PISTON RING AND CONNECTING ROD DISASSEMBLY AND REASSEMBLY 

Reference: CRANKSHAFT PIN AND CONNECTING ROD BEARINGS INSPECTION 

1. Apply engine oil to pistons, piston rings, cylinder walls, connecting rod bearings and crankshaft pins.
   NOTE: Do not apply engine oil between connecting rod and bearing or between connecting rod bearing cap and bearing.
2. Install connecting rod bearing to connecting rod or bearing cap as follows:
   1. Fit tab (1) of connecting rod bearing to groove (2) of connecting rod or bearing cap.
   2. Press bearing end (3) until it fully seats in connecting rod or bearing cap.
      Fig 1: Identifying Connecting Rod Bearing Installation Position

      Courtesy of SUZUKI OF AMERICA CORP.
3. When installing piston and connecting rod assembly into cylinder bore, direct front mark (1) on piston head to crankshaft pulley side (2).
   Fig 2: Identifying Piston Mark

   Courtesy of SUZUKI OF AMERICA CORP.
4. Install piston and connecting rod assembly into cylinder bore. Use special tool to compress rings. Guide connecting rod into place on crankshaft.

   Tap piston head with a hammer handle to install piston into bore. Hold ring compressor firmly against cylinder block until all piston rings have entered in cylinder bore.

   Special Tool 

   1. 09916-77310 
   Fig 3: Installing Piston And Connecting Rod Assembly Into Cylinder Bore

   Courtesy of SUZUKI OF AMERICA CORP.
5. Install connecting rod bearing cap (1) as follows:
   NOTE:

   • Before installing connecting rod bearing cap, check the cap bolts for deformation. Refer to "CONNECTING ROD BOLT DEFORMATION " under Piston Pins and Connecting Rods Inspection  .
   • Tighten connecting rod bearing cap bolt (3) gradually.
   1. Direct arrow mark (2) on connecting rod bearing cap (1) to crankshaft pulley side.
   2. Apply engine oil to bolt thread and seat of connecting rod bearing cap bolt.
   3. c) Tighten all connecting rod bearing cap bolts to 15 N.m (1.5 kgf-m, 11.0 lbf-ft) evenly and gradually.
   4. Retighten them to 45° in the same manner as in Step  c).
   5. Retighten them to 45° in the same manner as in Step  c).

      Tightening torque 

      Connecting rod bolt* (a): 15 N.m → +45° → +45° (1.5 kgf-m → +45° → +45°, 11.0 lbf-ft → +45° → +45° 

      Fig 4: Identifying Connecting Rod Bearing Cap Installation Position

      Courtesy of SUZUKI OF AMERICA CORP.
6. Install oil pump, see OIL PUMP ASSEMBLY REMOVAL AND INSTALLATION .
7. Install cylinder head, see Valve and Cylinder Head Removal and Installation .
8. Install engine assembly, see Engine Assembly Removal and Installation .