Suzuki Grand Vitara JB419. Service manual — part 116

Clutch: 5C-6

Installation

NOTE
Before installation, make sure that flywheel
surface and pressure plate surface have
been cleaned and dried thoroughly.

1) Install flywheel (1) to crankshaft and tighten new

bolts (2) to specification.

Special tool
(A): 09924–17811

Tightening torque
Flywheel bolt (a): 65 N·m (6.5 kgf-m, 47.0 lb-ft)

2) Using special tool, install input shaft bearing to

flywheel.

Special tool
(B): 09925–98210

3) Aligning clutch disc to flywheel center by using

special tool, install clutch cover (1) and bolts (2).
Then tighten bolts to specification.

NOTE

• While tightening clutch cover bolts,

compress clutch disc with special tool by
hand so that disc centered.

• Tighten cover bolts little by little evenly in

diagonal order.

Special tool
(A): 09924–17811
(C): 09923–36320

Tightening torque
Clutch cover bolt (b): 20 N·m (2.0 kgf-m, 14.5 lb-
ft)

4) Slightly apply grease to input shaft (1).

“A”: Grease 99000–25210 (SUZUKI Super
Grease I)

5) Join transmission assembly with engine.

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

NOTE
Turn crankshaft with wrench from front while
inserting transmission input shaft (1) to
clutch disc until splines mesh.

I5JB0A530020-01

IYSQ01530022-01

IYSQ01530023-01

1, “A”

I5JB0A530021-01

5C-7 Clutch:

Specifications

Tightening Torque Specifications

S5JB0B5307001

NOTE
The specified tightening torque is also described in the following.
“Clutch Cover, Clutch Disc and Flywheel Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.

Special Tools and Equipment

Recommended Service Material

S5JB0B5308001

Special Tool

S5JB0B5308002

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

Clutch master cylinder attaching nut

23

2.3

17.0

)

Clutch operating cylinder assembly mounting
bolt

10

1.0 7.5

)

Clutch fluid pipe flare nut

16

1.6

11.5

)

Flywheel bolt

65

6.5

47.0

)

Clutch cover bolt

20

2.0

14.5

)

Material

SUZUKI recommended product or Specification

Note

Grease

SUZUKI Silicone Grease

P/No.: 99000–25100

)

SUZUKI Super Grease I

P/No.: 99000–25210

)

09921–26020

09923–36320

Bearing remover

Clutch center guide (15 mm)

)

)

09924–17811

09925–98210

Flywheel holder

Input shaft bearing installer

)

/ ) / )

)

09930–30104
Sliding shaft
)

Table of Contents 6- i

6

Section 6

CONTENTS

Steering

Precautions . . . . . . . . . . . . . 6-*

Precautions. . . . . . . . . . . . . . . .. 6-*

Precautions for Steering . . . . . . . . . . 6-*

Steering General Diagnosis. . . . . .6A-*

Diagnostic Information and Procedures. . . 6A-*

Steering Symptom Diagnosis. . . . . . . ...6A-*

Steering Wheel and Column. . . . ... 6B-1

Precautions. . . . . . . . . . . . . . ... 6B-*

Service Precautions of Air Bag Steering

Wheel and Column . . . . . . . . . . . 6B-*

Precautions on Handling and Storage of Air

Bag Steering Wheel and Column. . . . . ...6B-*

Precautions on Disposal of Air Bag Steering

Wheel and Column . . . . . . . . . . . 6B-*

General Description . . . . . . . . . . . .6B-1

Steering Wheel and Column Construction . . .. 6B-1

Diagnostic Information and Procedures. . . 6B-*

Air Bag Steering Wheel and Column

Symptom Diagnosis . . . . . . . . . . ...6B-*

Air Bag Steering Wheel and Column

Inspection and Repair Required after
Accident . . . . . . . . . . . . . . . .6B-*

Diagnosis and Servicing of Air Bag Steering

Wheel and Column . . . . . . . . . . . 6B-*

Repair Instructions . . . . . . . . . . . ..6B-3

Checking Steering Column for Accident

Damage . . . . . . . . . . . . . . . .6B-*

Steering Wheel Removal and Installation . . . 6B-*

Contact Coil Cable Assembly Removal and

Installation. . . . . . . . . . . . . . . 6B-3

Contact Coil Cable Assembly Inspection . . . .6B-*
Centering Contact Coil Cable Assembly . . . ..6B-*

Steering Angle Sensor Removal and

Installation. . . . . . . . . . . . . . . 6B-4

Steering Angle Sensor Inspection. . . . . ... 6B-4
Steering Column Assembly Removal and

Installation. . . . . . . . . . . . . . . 6B-5

Steering Column Assembly Inspection . . . . 6B-*
Ignition Switch Cylinder Assembly Removal

and Installation (Without Keyless Start
System). . . . . . . . . . . . . . . ..6B-*

Steering Lock Assembly (Ignition Switch)

Removal and Installation. . . . . . . . . 6B-*

Adjustable Steering Column Release Lever

Inspection. . . . . . . . . . . . . . .. 6B-*

Steering Upper Shaft Assembly Removal and

Installation . . . . . . . . . . . . . . . 6B-*

Steering Upper Shaft Assembly Inspection. . . 6B-*
Steering Lower Shaft Assembly Removal and

Installation . . . . . . . . . . . . . . . 6B-*

Specifications. . . . . . . . . . . . . ...6B-7

Tightening Torque Specifications. . . . . . 6B-7

Power Assisted Steering System. . ... 6C-1

Precautions. . . . . . . . . . . . . . ... 6C-*

P/S System Note. . . . . . . . . . . . . 6C-*

General Description . . . . . . . . . . . .6C-1

P/S System Construction . . . . . . . . . 6C-1
Steering Gear Case Construction . . . . . ...6C-1
P/S Pump Construction. . . . . . . . . ...6C-2

Schematic and Routing Diagram. . . . . . 6C-*

P/S Fluid Flow Diagram . . . . . . . . . .. 6C-*

Diagnostic Information and Procedures. . . 6C-2

P/S System Symptom Diagnosis . . . . . . 6C-2

Steering Wheel Check . . . . . . . . . . 6C-*

Steering Force Check . . . . . . . . . . .6C-3

Steering Wheel Recovery Check . . . . . . 6C-*

Hydraulic Pressure in P/S Circuit Check. . . .6C-4

Repair Instructions . . . . . . . . . . . ..6C-6

P/S Fluid Change . . . . . . . . . . . . 6C-*

P/S Fluid Level Check. . . . . . . . . . .6C-6
P/S Fluid Leakage Check. . . . . . . . . 6C-6

P/S System Air Bleeding Procedure . . . . ... 6C-*

P/S Pump and A/C Compressor (If Equipped)

Drive Belt Inspection . . . . . . . . . . .6C-6

P/S Pump and A/C Compressor (If Equipped)

Drive Belt Removal and Installation . . . . .. 6C-*

Steering Rack Boot Check . . . . . . . . .. 6C-*
Tie-Rod End Boot Check . . . . . . . . . 6C-*
Tie-Rod End Removal and Installation. . . . 6C-*
Tie-Rod End Ball Joint Inspection . . . . . ... 6C-*
P/S Gear Case Assembly Components . . . .. 6C-*

P/S Gear Case Assembly Removal and

Installation . . . . . . . . . . . . . . .6C-7

Steering Gear Case Mount Bushing Removal

and Installation . . . . . . . . . . . . .. 6C-*

NOTE
For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual
mentioned in the “FOREWORD” of this manual.

6-ii Table of Contents

Steering Gear Case Mount Bushing

Inspection. . . . . . . . . . . . . . .. 6C-*

Rack Boot / Tie-Rod Removal and Installation . 6C-*

P/S Hose / Pipe Components . . . . . . . .6C-9
P/S Pump Removal and Installation. . . . ..6C-10
P/S Pump Assembly Components . . . . . 6C-10
P/S Pump Inspection. . . . . . . . . . .6C-10

Specifications . . . . . . . . . . . . . .6C-11

Tightening Torque Specifications. . . . . ..6C-11

Special Tools and Equipment . . . . . . ...6C-11

Recommended Service Material . . . . . . . 6C-*

Special Tool . . . . . . . . . . . . . ..6C-11