2006 SUZUKI SWIFT Piston ring

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-44
Pistons, Piston Rings, Connecting Rods and Cylinders ComponentsS7RS0B1406029
1. Top ring 6. Connecting rod bearing cap : See “B”: Tighten15 N
⋅m (1.5 kgf-m, 11.0 lb-ft), 45 °
and 45 ° by the specified procedure.
2. 2nd ring 7. Connecting rod bearing : Apply engine oil to sliding surface of each
part.
3. Oil ring 8. Piston pin : Do not reuse.
4. Piston 9. Piston pin circlip
5. Connecting rod : See “A” 10. Connecting rod bearing cap bolt
: See “C”
“A”: Apply engine oil to sliding surface except inner surface of big end.
“B”: Point arrow mark on cap to crankshaft pulley side.
“C”: Make sure bearing cap bolt diameter when reuse it due to plastic deformation tightening. Refer to “Piston Pins and Connecti ng Rods Inspection”.
(a)1
2
3
9
4
5
6 10
7 8
9
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Downloaded from www.Manualslib.com manuals search engine 1D-45 Engine Mechanical:
Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation
S7RS0B1406030
Removal1) Remove engine assembly from vehicle referring to “Engine Assembly Removal and Installation”.
2) Remove cylinder head referring to “Valves and Cylinder Head Removal and Installation”.
3) Mark cylinder number on all pistons, connecting rods
and connecting rod caps using silver pencil or quick
drying paint.
4) Remove rod bearing caps.
5) Decarbonize top of cylinder bore before removing piston from cylinder.
6) Push piston and connecting rod assembly out through the top of cylinder bore.
Installation 1) Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crank pins.
NOTE
Do not apply oil between connecting rod and
bearing or between bearing cap and bearing.

2) When installing piston and connecting rod assembly into cylinder bore, point front mark or arrow mark (1)
on piston head to crankshaft pulley side. 3) 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
4) Install bearing cap (1): Point arrow mark (2) on cap to crankshaft pulley
side.
After applying engine oil to bearing cap bolts and
tighten bolts gradually as follows.
a) Tighten all bolts to 15 N ⋅m (1.5 kgf-m, 11.0 lb-ft).
b) Retighten them to 45 °.
c) Repeat Step b) once again.
NOTE
Before installing bearing cap, make sure that
checking for bearing cap bolt deformation.
Refer to “Piston Pins and Connecting Rods
Inspection”.

Tightening torque
Connecting rod bearing cap bolt: 15 N ⋅m (1.5
kgf-m, 11.0 lb-ft) and then retighten by
turning through 45 ° twice
5) Install cylinder head referring to “Valves and Cylinder Head Removal and Installation”.
A: Crankshaft pulley side
B: Flywheel side
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-46
Pistons, Piston Rings, Connecting Rods and
Cylinders Disassembly and Assembly
S7RS0B1406031
Disassembly1) 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 circlip (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 figure.
NOTE
Be sure to position front mark or arrow mark
(4) on piston and oil hole (5) of connecting
rod at specified position as shown in 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 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 discrimination mark (4) 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.
4) After installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in figure.
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1. 1st ring end gap 3. Oil ring upper rail gap
2. 2nd ring end gap and oil ring spacer gap 4. Oil ring lower rail gap
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Downloaded from www.Manualslib.com manuals search engine 1D-47 Engine Mechanical:
Cylinders, Pistons and Piston Rings InspectionS7RS0B1406032
Cylinder
Visual inspection
Inspect cylinder walls for scratches, roughness or ridges
which indicate excessive wear. If cylinder bore is very
rough or deeply scratched, or ridged, rebore cylinder and
use over size piston.
Cylinder bore diameter, taper and out-of-round
Using a cylinder gauge (1), measure cylinder bore in
thrust and axial directions at two positions (“a” and “b”)
as shown in figure.
If any of the following conditions is noted, rebore
cylinder.1) Cylinder bore dia. exceeds limit.
2) Difference of measurements at two positions exceeds taper limit.
3) Difference between thrust and axial measurements exceeds out-of-round limit.
Cylinder bore diameter
Standard: 78.000 – 78.014 mm (3.0709 – 3.0714
in.)
Limit: 78.114 mm (3.075 in.)
Cylinder taper and out-of-round
Limit: 0.10 mm (0.004 in.)
NOTE
If any one of four cylinders has to be rebored,
rebore all four to the same next oversize.
This is necessary for the sake of uniformity
and balance.

Piston
Visual inspection
Inspect piston for faults, cracks or other damages.
Damaged or faulty piston should be replaced.
Piston diameter
As indicated in the figure, piston diameter should be
measured at a position “a” from piston skirt end in the
direction perpendicular to piston pin.
Piston diameter specification
Standard size (used piston):
77.953 – 77.968 mm (3.0690 – 3.0696 in.)
Standard size (new piston with coating):
77.963 – 77.990 mm (3.0694 – 3.0704 in.)
Oversize (0.05 mm (0.0196 in.)):
78.453 – 78.468 mm (3.0887 – 3.0893 in.)
“a”: 50 mm (1.96 in.) “b”: 95 mm (3.74 in.)
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“a”: 7.0 mm (0.28 in.)
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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-48
Piston clearance
Measure cylinder bore diameter and piston diameter to
find their difference which is piston clearance. Piston
clearance should be within spec ification as follows. If it is
out of specification, rebore cylinder and use oversize
piston.
NOTE
Cylinder bore diameters used here are
measured in thrust direction at two positions.

Piston clearance
Standard (used piston): 0.032 – 0.061 mm (0.0013 –
0.0024 in.)
Standard (new piston with coating): 0.010 – 0.051
mm (0.0004 – 0.0020 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
clearance between ring and ring land by using thickness
gauge (2). If clearance is ou t of specification, replace
piston.
Ring groove clearance
Piston Ring
Piston ring end gap
To measure end gap, insert piston ring (2) into cylinder
bore and then measure the gap by using thickness
gauge (1).
If measured gap exceeds limit, replace ring.
NOTE
Decarbonize and clean top of cylinder bore
before inserting piston ring.

Ring groove clearance
“a”: 7.0 mm (0.28 in.)
Standard Limit
Top ring 0.04 – 0.08 mm
(0.0016 – 0.0031 in.) 0.12 mm (0.0047 in.)
2nd ring 0.03 – 0.07 mm
(0.0012 – 0.0027 in.) 0.10 mm (0.0394 in.)
Oil ring 0.04 – 0.12 mm
(0.0016 – 0.0047 in.) —
I4RS0A140022-01
Item Standard
Limit
To p r i n g 0.20 – 0.33 mm
(0.0079 – 0.0129 in.) 0.7 mm (0.0276 in.)
2nd ring 0.43 – 0.56 mm
(0.0170 – 0.0220 in.) 1.0 mm (0.0394 in.)
Oil ring 0.10 – 0.40 mm
(0.0040 – 0.0157 in.) 0.7 mm (0.0276 in.)
“a”: 120 mm (4.72 in.)
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Downloaded from www.Manualslib.com manuals search engine 1D-53 Engine Mechanical:
Main Bearings, Crankshaft and Cylinder Block ComponentsS7RS0B1406035
(a)
(c)
(d)(e)
(b)
(f)
(f)
(f)
(g)
(h)
12
3
4
5 67
8910
11 15
12 13
14 16
17
18 19
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23 24
25
26
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1. CKP sensor : See “A” 12. Input shaft bearing 23. Sensor plate bolt
2. Knock sensor 13. Flywheel or drive plate 24. Oil pressure switch 3. Cylinder block 14. Main bearing cap 25. Piston cooling nozzle
4. Venturi plug 15. Flywheel or drive plate bolt 26. Piston cooling valve
5. Main bearing : See “B” 16. Rear oil seal housing mounting bolt : 22 N
⋅m (2.2 kgf-m, 16.0 lb-ft)
6. Sensor plate 17. Main bearing cap No.2 bolt : 5 N ⋅m (0.5 kgf-m, 4.0 lb-ft)
7. Crankshaft timing sprocket key 18. Main bearing cap No.1 bolt : See “D”:70 N
⋅m (7.0 kgf-m, 51.0 lb-ft)
8. Crankshaft 19. O-ring : Tighten 25 N ⋅m (2.5 kgf-m, 18.0 lb-ft) by the specified
procedure.
9. Thrust bearing 20. Oil filter adapter case : Tighten 30 N ⋅m (3.0 kgf-m, 22.0 lb-ft), 50 N⋅m (5.0
kgf-m, 36.5 lb-ft) and 60 ° by the specified procedure.
10. Rear oil seal housing : See “C” 21. Oil filter adapter bolt : 11 N
⋅m (1.1 kgf-m, 8.0 lb-ft)
11. Rear oil seal 22. Spring pin : 13 N ⋅m (1.3 kgf-m, 9.5 lb-ft)

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-54
Main Bearings, Crankshaft and Cylinder Block
Removal and Installation
S7RS0B1406036
Removal1) Remove engine assembly from vehicle referring to “Engine Assembly Removal and Installation”.
2) Remove clutch cover, clut ch disc and flywheel (drive
plate for A/T) by using special tool.
Special tool
(A): 09924–17811
3) Remove piston and connecting rod referring to “Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation”.
4) Remove rear oil seal housing (1). 5) Loosen main bearing cap No.1 and No.2 bolts in
such order as indicated in figure and remove them.
6) Remove crankshaft from cylinder block.
7) Remove piston cooling valves and nozzles, if necessary.
“A”: When servicing CKP sensor, refer to “CMP Sensor Removal and Installation in Section 1C”. :25 N
⋅m (2.5 kgf-m, 18.0 lb-ft)
“B”: Upper half of bearing has an oil groove. : Do not reuse.
“C”: Apply sealant 99000-31250 to mating surface. : Apply engine oil to inside / sliding surface.
“D”: Make sure main bearing cap No.1 bolt deformation when reuse it due to plastic deformation tightening referring to “Main Bearings Inspection”.
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Downloaded from www.Manualslib.com manuals search engine 1D-55 Engine Mechanical:
Installation
NOTE
• Use new bearing cap No.1 bolts. They are deformed once they are used because they
are plastic deformation tightening bolts.
• All parts to be insta lled 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, bearing caps, connecting rods, rod bearings, rod bearing
caps, pistons and piston rings are in
combination sets. Do not disturb such
combination and make sure that each part
goes back to where it came from, when
installing.

1) Install sensor plate (1) to crankshaft (2) and tighten bolts to spec ified torque.
NOTE
When installing sensor plate, align spring pin
(3) on crankshaft and hole of sensor plate.

Tightening torque
Sensor plate bolt (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft) 2) Install piston cooling valves and nozzles, if removed.
NOTE
Install piston cooling valve while matching
piston cooling nozzle (1) to positioning (3) of
cylinder block when installed piston cooling
valve (2).

Tightening torque
Piston cooling valve (a): 11 N·m (1.1 kgf-m, 8.0
lb-ft)
3) 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.
4) Confirm that dowel pins (3 ) are installed to intake
side of each journal.
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