Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Reassembly - Suzuki Jimny Workshop Manual
1D
Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Reassembly
Disassembly
1)
Using piston ring expander, remove top and 2nd compression rings and oil ring from piston.
2)
Remove piston pin from connecting rod as follows.
a)
Using flat head screw driver (2) or the like, remove piston pin circlips (1) as shown.
b)
Remove piston pin (1) from piston (2).
Reassembly
NOTE:
Whenever piston is replaced, select applicable piston referring to “Selection of Piston” in
Pistons, Piston Rings, Connecting Rods and Cylinders Inspection:K9K
.
1)
Clean carbon from piston head and ring grooves using a suitable tool.
2)
Install connecting rod bearings (3) to connecting rod (1) and bearing cap (2) as follows.
a)
Distinguish connecting rod bearing between connecting rod side connecting rod bearing and bearing side connecting rod bearing (4) measuring its width before installing.
Connecting rod side connecting rod bearing width “a”:
20.500 – 20.750 mm (0.80709 – 0.81692 in.)
Bearing cap side connecting rod bearing width “b”:
17.500 – 17.750 mm (0.68898 – 0.69881 in.)
b)
Install special tool (B) to special tool (A).
NOTE:
Be sure to install special tool (B) to specified direction as shown.
| 1. | Mark “B” |
c)
Install connecting rod (1) and connecting rod bearing to special tool (A and B) as shown.
d)
Install connecting rod bearing to connecting rod pushing special tool (B) as shown.
e)
Install special tool (B) to special tool (A).
NOTE:
Be sure to install special tool (B) to specified direction as shown.
f)
Install bearing cap (2) and connecting rod bearing to special tool (A and B) as shown.
g)
Install connecting rod bearing to bearing cap pushing special tool (B) as shown.
| 1. | Mark “A” |
3)
Install piston pin to piston and connecting rod as follows.
a)
After applying engine oil to piston pin and piston pin holes in piston and connecting rod, fit connecting rod to piston so that flat part (2) of connecting rod bearing and arrow mark (1) come on the same side, and insert piston pin to piston and connecting rod.
b)
Install piston pin circlips.
c)
Position opening of piston pin circlip to opposite side of removal and fitting channel (4).
| 5. | Flywheel side |
4)
Install piston rings to piston noting the following.
NOTE:
•
As indicated in the figure, 1st and 2nd rings have “TOP” 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 and shape.
Distinguish 1st ring from 2nd ring by referring to the figure.
• When installing oil ring, install spiral ring (3) first and then rail (4).
• 1st ring (1) differs from 2nd ring (2) in thickness and shape.
Distinguish 1st ring from 2nd ring by referring to the figure.
• When installing oil ring, install spiral ring (3) first and then rail (4).