Suzuki Grand Vitara JB419. Service manual — part 115

Clutch: 5C-2

Component Location

Clutch Fluid Pipe and Hose Location

S5JB0B5303001

Repair Instructions

Air Bleeding of Clutch System

S5JB0B5306014

CAUTION

!

• Brake fluid is extremely damaging to paint.

If fluid should accidentally touch painted
surface, immediately wipe fluid from paint
and clean painted surface.

• When operating the pedal stroke for air

bleeding of clutch system, after releasing
the clutch pedal, be sure to wait 1 second
or more before depressing it again.
Otherwise, the oil seal of operating
cylinder will be damaged, resulting in oil
leakage.

Bleed air from clutch system. Refer to “Air Bleeding of
Brake System in Section 4A in related manual” for air
bleeding procedure.

1

1

2

2

2

3

4

5

5

6

6

7

[A]

I5JB0A530002-03

[A]: Right-hand steering vehicle

3. Clutch fluid hose

6. Brake master cylinder reservoir

1. Clutch master cylinder

4. Clutch operating cylinder assembly

7. Clutch fluid pipe joint

2. Clutch fluid pipe

5. Clutch reservoir hose

3

1

2

4

I5JB0A530017-01

5C-3 Clutch:

Clutch Master Cylinder Removal and
Installation

S5JB0B5306005

CAUTION

!

• Do not allow fluid to get on painted

surfaces. It may cause painted surface
damage.

• Do not disassemble clutch master

cylinder.

Removal

1) Clean around reservoir cap of brake master cylinder

and take out fluid with syringe or such.

2) Detach main fuse box.
3) Disconnect fluid pipe (2) and reservoir hose (4) from

master cylinder assembly (1).

4) Remove clip (6) and push rod clevis pin (5).
5) Remove master cylinder attaching nuts (3).
6) Remove master cylinder assembly (1) and gasket.

Installation
Reverse removal procedure for installation noting the
following.
• Apply grease to push rod clevis pin (1).

“A”: Grease 99000–25100 (SUZUKI Silicone Grease)

• Tighten master cylinder attaching nuts (2) to specified

torque.

Tightening torque
Clutch master cylinder attaching nut (a): 23 N·m (
2.3 kgf-m, 17.0 lb-ft)

• Fill reservoir with specified brake fluid and check fluid

leakage.

• After installation, bleed air from clutch system and

check clutch pedal free travel. Refer to “Air Bleeding
of Clutch System” for air bleeding procedure.

1

2

3

4

3

6

5

I5JB0A530013-01

1, “A”

2, (a)

2, (a)

I5JB0A530014-01

I5JB0A530015-03

Clutch: 5C-4

Clutch Operating Cylinder Assembly Removal
and Installation

S5JB0B5306007

CAUTION

!

• Do not allow fluid to get on painted

surfaces. It may cause painted surface
damage.

• Do not disassemble clutch operating

cylinder assembly.

Removal

1) Clean around reservoir cap of brake master cylinder

and take out fluid with syringe or such.

2) Dismount transmission assembly referring to

“Manual Transmission Assembly Dismounting and
Remounting in Section 5B”.

3) Loosen clutch fluid pipe flare nut (1) of clutch

operating cylinder assembly (2).

4) Remove clutch pipe joint sleeve (3) from

transmission front case and then remove clutch fluid
pipe (4).

5) Remove clutch operating cylinder assembly from

transmission front case.

Installation

1) Install clutch operating cylinder assembly (2) to

transmission front case. Tighten mounting bolts to
specified torque.

Tightening torque
Clutch operating cylinder assembly mounting bolt
(a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)

2) Connect clutch fluid pipe (4) to clutch operating

cylinder assembly temporarily.

3) Install clutch pipe joint sleeve (3) to transmission

front case securely and then tighten clutch fluid pipe
flare nut (1) to specified torque.

Tightening torque
Clutch fluid pipe flare nut (b): 16 N·m (1.6 kgf-
m, 11.5 lb-ft)

4) Remount transmission assembly referring to

“Manual Transmission Assembly Dismounting and
Remounting in Section 5B”.

5) Fill reservoir with specified brake fluid and check for

fluid leakage.

6) Bleed air from system and check clutch pedal free

travel. Refer to “Air Bleeding of Clutch System” for
air bleeding procedure.

Clutch Operating Cylinder Assembly Inspection
Check clutch fluid leakage, spring for damage and
bearing for smooth rotation. If malfunction is found,
replace clutch operating cylinder assembly.

3

1

2

4

I5JB0A530017-01

3

1, (b)

2

4

(a)

I5JB0A530018-01

I5JB0A530015-03

5C-5 Clutch:

Clutch Cover, Clutch Disc and Flywheel Components

S5JB0B5306008

Clutch Cover, Clutch Disc and Flywheel
Removal and Installation

S5JB0B5306009

Removal

1) Dismount transmission assembly referring to

“Manual Transmission Assembly Dismounting and
Remounting in Section 5B”.

2) Hold flywheel stationary with special tool and remove

clutch cover bolts (1), clutch cover (2) and clutch
disc.

Special tool
(A): 09924–17811

3) Pull out input shaft bearing (1) by using special tools.

Special tool
(A): 09921–26020
(B): 09930–30104

4) Remove flywheel from crankshaft.

I5JB0A530022-01

1. Input shaft bearing

4. Clutch cover

: 20 N

⋅m (2.0 kgf-m, 14.5 lb-ft)

2. Flywheel

5. Clutch cover bolt

: 65 N

⋅m (6.5 kgf-m, 47.0 lb-ft)

3. Clutch disc

6. Flywheel bolt

: Do not reuse.

IYSQ01530019-01

I2RH01530023-01