2005 SUZUKI JIMNY piston

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Piston clearance:
Measure cylinder bore diameter and piston diameter to find
their difference which is piston clearance. Piston clearance
should be within specification as given below. If it is out of
specification, rebore cylinder and use oversize piston.
Piston clearance
Standard : 0.032 – 0.061 mm (0.0013 – 0.0024 in.)
Limit : 0.161 mm (0.0063 in.)
Ring groove clearance:
Before checking, piston grooves must be clean, dry and free
of carbon deposits.
Fit new piston ring (1) into piston groove, and measure clear-
ance between ring and ring land by using thickness gauge
(2).
If clearance is out of limit, replace piston.
Ring groove clearance
Top ring
Standard : 0.03 – 0.07 mm (0.0012 – 0.0028 in.)
Limit : 0.12 mm (0.0047 in.)
2nd ring
Standard : 0.02 – 0.06 mm (0.0008 – 0.0024 in.)
Limit : 0.10 mm (0.0039 in.)
Oil ring
Standard : 0.03 – 0.17 mm (0.0012 – 0.0067 in.)
Piston Pin
Check piston pin, connecting rod small end bore and piston
bore for wear or damage, paying particular attention to con-
dition of small end bore bush. If pin, connecting rod small
end bore or piston bore is badly worn or damaged, replace
pin, connecting rod and/or piston. NOTE:
Cylinder bore diameters used here are measured in
thrust direction at two positions.
“a” : 19.5 mm (0.77 in.)

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Piston pin clearance:
Check piston pin clearance in small end and piston. Replace
connecting rod and/or piston if its small end is badly worn or
damaged or if measured clearance exceeds limit.
Piston pin clearance in connecting rod small end
0.003 – 0.014 mm (0.0001 – 0.0006 in.)
Piston pin clearance in piston
0.006 – 0.017 mm (0.00024 – 0.00067 in.)
Small-end bore for connecting rod
20.003 – 20.011 mm (0.7875 – 0.7878 in.)
Piston pin diameter
19.997 – 20.000 mm (0.7873 – 0.7874 in.)
Piston bore
20.006 – 20.014 mm (0.7876 – 0.7880 in.)
Piston Rings
To measure end gap, insert piston ring (1) into cylinder bore and
then measure the gap by using thickness gauge (2).
If measured gap is out of specification, replace ring.
Piston ring end gap
Connecting Rod
Big-end side clearance:
Check big-end of connecting rod for side clearance, with rod
fitted and connected to its crank pin in the normal manner. If
measured clearance is found to exceed its limit, replace con-
necting rod.
Side clearance for connecting rod big-end
Standard : 0.25 – 0.40 mm (0.0098 – 0.0157 in.)
Limit : 0.55 mm (0.0217 in.)
NOTE:
Decarbon and clean top of cylinder bore before inserting
piston ring.
Item Standard Limit
Top ring0.20 – 0.35 mm
(0.0079 – 0.0138 in.)0.7 mm
(0.0276 in.)
2nd ring0.30 – 0.45 mm
(0.0118 – 0.0177 in.)1.0 mm
(0.0039 in.)
Oil ring0.20 – 0.70 mm
(0.0079 – 0.0276 in.)1.5 mm
(0.059 in.)
“a” : 120 mm (4.72 in.)

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6) If clearance can not be brought to within its limit even by
using a new standard size bearing, regrind crankpin to
undersize and use 0.25 mm undersize bearing.
ASSEMBLY
1) 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 figure.
c) Insert piston pin to piston and connecting rod.
d) Install piston pin circlips (3).
2) Install piston rings to piston :
a) As indicated in 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.
b) 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 figure.
c) When installing oil ring (3) install spacer first and then two
rails.
3) After installing three rings (1st, 2nd and oil rings), distribute
their end gaps as shown in figure. NOTE:
After checking the rod bearing clearance, make sure to
check connecting rod bolt diameter.
Refer to “Inspection” of “Connecting Rod”.
NOTE:
Circlip should be installed with its cut part facing as
shown in figure. Install so that circlip end gap comes
within such range as indicated by arrow.
1. Arrow mark
2. 1st ring end gap
3. 2nd ring end gap and oil ring spacer gap
4. Oil ring upper rail gap
5. Oil ring lower rail gap

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INSTALLATION
1) Apply engine oil to pistons, rings, cylinder walls, connecting
rod bearings and crankpins.
2) Install guide hoses (1) over connecting rod bolts.
These guide hoses protect crank pin and threads of rod bolt
from damage during installation of connecting rod and piston
assembly.
3) When installing piston and connecting rod assembly into cyl-
inder bore, point front mark on piston head to crankshaft pul-
ley side.
4) Install piston and connecting rod assembly into cylinder
bore. Use special tool (Piston ring compressor) to compress
rings. Guide connecting rod into place on crankshaft.
Using a hammer handle, tap piston head to install piston into
bore. Hold ring compressor firmly against cylinder block until
all piston rings have entered cylinder bore.
Special tool
(A) : 09916-77310 NOTE:
Do not apply oil between connecting rod and bearing or
between bearing cap and bearing.
A : Crankshaft pulley side
B : Flywheel side

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REMOVAL
1) Remove engine assembly from vehicle as previously out-
lined.
2) Remove clutch cover, clutch disc and flywheel (drive plate
for A/T) by using special tool.
Special tool
(A) : 09924-17810
3) Remove the following parts from engine as previously out-
lined.
Oil pan and oil pump strainer
Intake manifold and exhaust manifold
Cylinder head cover
Timing chain cover
Timing chain guide, chain tensioner adjuster, chain ten-
sioner, timing chain and crankshaft timing sprocket
Camshaft, tappet and shim
Cylinder head assembly
Piston and connecting rod
4) Remove rear oil seal housing (1).
5) Loosen bearing cap No.1 and No.2 bolts in such order as
indicated in figure and remove them.
6) Remove crankshaft from cylinder block.

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Flywheel
If ring gear is damaged, cracked or worn, replace flywheel.
If the surface contacting clutch disc is damaged, or exces-
sively worn, replace flywheel.
Check flywheel for face runout with a dial gauge.
If runout exceeds its limit, replace flywheel.
Flywheel runout
Limit : 0.2 mm (0.0079 in.)
Sensor Plate
Check sensor plate for crack or damage. If malcondition is
found, replace it.
Cylinder Block
Distortion of gasketed surface
Using straightedge and thickness gauge, check gasketed
surface for distortion and, if flatness exceeds its limit, correct
it.
Cylinder block flatness
Limit : 0.05 mm (0.0020 in.)
Honing or reboring cylinders
1) When any cylinder needs reboring, all other cylinders must
also be rebored at the same time.
2) Select oversized piston according to amount of cylinder
wear.
Oversize piston diameter
Size Piston diameter
Oversize 0.5078.453 – 78.468 mm
(3.0887 – 3.0893 in.)

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3) Using micrometer, measure piston diameter.
Measurement position for piston diameter
“a” : 19.5 mm (0.77 in.)
4) Calculate cylinder bore diameter to be rebored as follows.
D = A + B – C
D : Cylinder bore diameter to be rebored.
A : Piston diameter as measured.
B : Piston clearance = 0.02 –0.04 mm (0.0008 – 0.0016 in.)
C : Allowance for honing = 0.02 mm (0.0008 in.)
5) Rebore and hone cylinder to calculated dimension.
6) Measure piston clearance after honing.
NOTE:
Before reboring, install all main bearing caps in place
and tighten to specification to avoid distortion of bearing
bores.

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INSTALLATION
1) Install sensor plate (1) to crankshaft (2) and tighten bolts to
specified torque.
Tightening torque
Sensor plate bolts (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
2) Install main bearings to cylinder block.
Upper half of bearing (1) has an oil groove (2).
Install it to cylinder block (3), and the other half without oil
groove to bearing cap.
Make sure that two halves are painted in the same color.
3) Install thrust bearings (1) to cylinder block between No.2 and
No.3 cylinders. Face oil groove (2) sides to crank webs.
4) Confirm that dowel pins(3) are installed to intake side of
each journal. NOTE:
All parts to be installed must be perfectly clean.
Be sure to oil crankshaft journals, journal bearings,
thrust bearings, crankpins, connecting rod bearings,
pistons, piston rings and cylinder bores.
Journal bearings, bearings caps, connecting rods, rod
bearings, rod bearing caps, pistons and piston rings
are in combination sets. Do not disturb such combina-
tion and make sure that each part goes back to where
it came from, when installing.
NOTE:
When installing sensor plate, align spring pin (3) on
crankshaft and hole of sensor plate.