Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly - Suzuki Jimny Workshop Manual
1D
Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly
Disassembly
1)
Using piston ring expander, remove two compression rings (Top and 2nd) and oil ring from piston.
2)
Remove piston pin from connecting rod as follows.
a)
Ease out piston pin circlips (1), as shown.
b)
Force piston pin out.
Assembly
1)
Decarbonize piston head and ring grooves using a suitable tool.
2)
Install piston pin to piston (1) and connecting rod (2):
a)
After applying engine oil to piston pin and piston pin holes in piston and connecting rod.
b)
Fit connecting rod as shown in the figure.
c)
Insert piston pin to piston and connecting rod.
d)
Install piston pin circlips (3).
NOTE:
Circlip should be installed with its cut part facing as shown in the figure. Install so that circlip end gap comes within such range as indicated by arrow.
3)
Install piston rings to piston:
•
As indicated in the figure, 1st and 2nd rings have “T” mark respectively. When installing these piston rings to piston, direct marked side of each ring toward top of piston.
• 1st ring (1) differs from 2nd ring (2) 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 (3), install spacer first and then two rails.
• 1st ring (1) differs from 2nd ring (2) 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 (3), install spacer first and then two rails.
4)
After installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in the figure.
| 1. | Arrow mark | 4. | Oil ring upper rail gap |
| 2. | 1st ring end gap | 5. | Oil ring lower rail gap |
| 3. | 2nd ring end gap and oil ring spacer gap |