Suzuki Grand Vitara JB627. Manual — part 254

5C-7 Clutch:

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 Brake System in Section 4A” for air bleeding
procedure.

Clutch Master Cylinder Inspection

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• Check master cylinder (1) for damage and fluid

leakage, boot for damage and deterioration, gasket
for damage and deterioration.

• Check for push rod clevis distance “a” and clevis pin

hole diameter “b” as shown.

If any malfunction is found, replace master cylinder.

Push rod clevis distance “a”:
106.1 – 107.1 mm (4.18 – 4.22 in.)

Clevis pin hole diameter “b”:
10.05 – 10.15 mm (0.396 – 0.399 in.)

Clutch Operating Cylinder Assembly Removal
and Installation

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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.

1, “A”

2, (a)

2, (a)

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I5JB0A530015-03

“b”

“a”

1

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3

1

2

4

I5JB0A530017-01

Clutch: 5C-8

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 Brake System in
Section 4A” 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.

Clutch Cover, Clutch Disc and Flywheel Components

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3

1, (b)

2

4

(a)

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1. Input shaft bearing

4. Clutch cover

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft)

2. Flywheel

5. Clutch cover bolt

: 68.5 N

⋅m (6.9 kgf-m, 49.5 lb-ft)

3. Clutch disc

6. Flywheel bolt

: Do not reuse.

5C-9 Clutch:

Clutch Cover, Clutch Disc and Flywheel
Removal and Installation

S6JB0B5306009

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.

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): 68.5 N·m (6.9 kgf-m, 49.5 lb-ft)

2) Using special tool, install input shaft bearing to

flywheel.

Special tool
(B): 09925–98210

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Clutch: 5C-10

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): 23 N·m (2.3 kgf-m, 17.0 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.

Clutch Cover, Clutch Disc and Flywheel
Inspection

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Input Shaft Bearing
Check bearing for smooth rotation and replace it if
abnormality is found.

Clutch Disc
Measure depth of rivet head depression, i.e. distance
between rivet head and facing surface. If depression is
found to have reached service limit at any of holes,
replace disc assembly.

Rivet head depth
Standard: 1.5 mm (0.06 in.)
Service limit: 0.5 mm (0.02 in.)

Clutch Cover
• Check diaphragm spring for abnormal wear or

damage.

• Inspect pressure plate for wear or heat spots.
If abnormality is found, replace it as assembly. Do not
disassemble it into diaphragm and pressure plate.

Flywheel
Check surface contacting clutch disc for abnormal wear
or heat spots. Replace or repair as required.

IYSQ01530023-01

1, “A”

I5JB0A530021-01

IYSQ01530025-01