Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 358

5C-7 Clutch:

Clutch Master Cylinder Removal and
Installation

S6JB0A5306005

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 “Clutch Pedal
Free Travel Check” and “Air Bleeding of Brake
System in Section 4A” for air bleeding procedure.

Clutch Master Cylinder Inspection

S6JB0A5306006

• 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.)

1

2

3

4

3

6

5

I5JB0A530013-01

1, “A”

2, (a)

2, (a)

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I5JB0A530015-03

“b”

“a”

1

I5JB0A530016-01

Clutch: 5C-8

Clutch Operating Cylinder Assembly Removal
and Installation

S6JB0A5306007

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: For Petrol Engine Model in Section 5B”
or “Manual Transmission Assembly Dismounting and
Remounting: For Diesel Engine Model 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: For Petrol Engine Model in Section 5B”
or “Manual Transmission Assembly Dismounting and
Remounting: For Diesel Engine Model 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 “Clutch Pedal Free Travel Check”
and “Air Bleeding of Brake System in Section 4A” for
air bleeding procedure.

Clutch Operating Cylinder Assembly Inspection

S6JB0A5306011

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-9 Clutch:

Clutch Cover, Clutch Disc and Flywheel Components

S6JB0A5306008

Clutch Cover, Clutch Disc and Flywheel
Removal and Installation

S6JB0A5306009

Removal

1) Dismount transmission assembly referring to

“Manual Transmission Assembly Dismounting and
Remounting: For Petrol Engine Model in Section 5B”
or “Manual Transmission Assembly Dismounting and
Remounting: For Diesel Engine Model 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

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft) (petrol engine model)

20 N

⋅m (2.0 kgf-m, 14.5 lb-ft) (diesel engine model)

2. Flywheel

5. Clutch cover bolt

: 70 N

⋅m (7.0 kgf-m, 50.5 lb-ft) (M16 engine model)

68.5 N

⋅m (6.85 kgf-m, 49.5 lb-ft) (J20 engine model)

65 N

⋅m (6.5 kgf-m, 47.0 lb-ft) (F9Q engine model)

3. Clutch disc

6. Flywheel bolt

: Do not reuse.

IYSQ01530019-01

I6JB0A530002-01

Clutch: 5C-10

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 (M16 engine model) (a): 70 N·m (
7.0 kgf-m, 50.5 lb-ft)
Flywheel bolt (J20 engine model) (a): 68.5 N·m (
6.9 kgf-m, 49.5 lb-ft)
Flywheel bolt (F9Q engine model) (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 (petrol engine model) (b): 23
N·m (2.3 kgf-m, 17.0 lb-ft)
Clutch cover bolt (diesel engine model) (b): 20
N·m (2.0 kgf-m, 14.5 lb-ft)

I5JB0A530020-01

IYSQ01530022-01

IYSQ01530023-01