Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 359

5C-11 Clutch:

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

S6JB0A5306010

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.

1, “A”

I5JB0A530021-01

IYSQ01530025-01

Clutch: 5C-12

Specifications

Tightening Torque Specifications

S6JB0A5307001

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

S6JB0A5308001

Special Tool

S6JB0A5308002

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

Clutch fluid pipe flare nut

16

1.6

11.5

)

/ )

Clutch fluid hose bracket nut

10

1.0

7.5

)

Clutch master cylinder attaching nut

23

2.3

17.0

)

Clutch operating cylinder assembly mounting
bolt

10

1.0 7.5

)

Flywheel bolt (M16 engine model)

70

7.0

50.5

)

Flywheel bolt (J20 engine model)

68.5

6.9

49.5

)

Flywheel bolt (F9Q engine model)

65

6.5

47.0

)

Clutch cover bolt (petrol engine model)

23

2.3

17.0

)

Clutch cover bolt (diesel engine model)

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
)

5C-13 Clutch:

Table of Contents 6- i

6

Section 6

CONTENTS

Steering

Precautions . . . . . . . . . . . . .6-1

Precautions. . . . . . . . . . . . . . . . 6-1

Precautions for Steering . . . . . . . . . ... 6-1

Steering General Diagnosis. . . . . 6A-1

Diagnostic Information and Procedures. . . 6A-1

Steering Symptom Diagnosis. . . . . . . .. 6A-1

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

Precautions. . . . . . . . . . . . . . ...6B-1

Service Precautions of Air Bag Steering

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

Precautions on Handling and Storage of Air

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

Precautions on Disposal of Air Bag Steering

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

Service Precautions of Steering Angle Sensor

(ESP

® model). . . . . . . . . . . . ...6B-1

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

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

Diagnostic Information and Procedures. . . 6B-3

Air Bag Steering Wheel and Column

Symptom Diagnosis . . . . . . . . . . .. 6B-3

Air Bag Steering Wheel and Column

Inspection and Repair Required after
Accident . . . . . . . . . . . . . . . 6B-3

Diagnosis and Servicing of Air Bag Steering

Wheel and Column . . . . . . . . . . ... 6B-3

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

Checking Steering Column for Accident

Damage . . . . . . . . . . . . . . . 6B-3

Steering Wheel Removal and Installation . . ... 6B-4
Contact Coil Cable Assembly Removal and

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

Contact Coil Cable Assembly Inspection . . . 6B-7
Centering Contact Coil Cable Assembly . . . . 6B-7
Steering Angle Sensor Removal and

Installation (ESP

® model). . . . . . . . .6B-8

Steering Angle Sensor Inspection (ESP

®

model) . . . . . . . . . . . . . . . ... 6B-8

Steering Column Assembly Removal and

Installation. . . . . . . . . . . . . . . 6B-8

Steering Column Assembly Inspection . . . .6B-10

Ignition Switch Cylinder Assembly Removal

and Installation (without Keyless Start
System) . . . . . . . . . . . . . . ...6B-10

Steering Lock Assembly (Ignition Switch)

Removal and Installation. . . . . . . . .6B-11

Adjustable Steering Column Release Lever

Inspection. . . . . . . . . . . . . . 6B-12

Steering Upper Shaft Assembly Removal and

Installation . . . . . . . . . . . . . ...6B-12

Steering Upper Shaft Assembly Inspection. ...6B-13
Steering Lower Shaft Assembly Removal and

Installation . . . . . . . . . . . . . ...6B-14

Specifications. . . . . . . . . . . . . .6B-15

Tightening Torque Specifications. . . . . ..6B-15

Special Tools and Equipment . . . . . . ...6B-15

Special Tool . . . . . . . . . . . . . ..6B-15

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

Precautions. . . . . . . . . . . . . . ...6C-1

P/S System Note. . . . . . . . . . . . .6C-1

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

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

Schematic and Routing Diagram. . . . . . 6C-3

P/S Fluid Flow Diagram . . . . . . . . . ..6C-3

Diagnostic Information and Procedures. . . 6C-3

P/S System Symptom Diagnosis . . . . . . 6C-3
Steering Wheel Check . . . . . . . . . . 6C-4
Steering Force Check . . . . . . . . . . .6C-5
Steering Wheel Recovery Check . . . . . . 6C-5
Idle Up System Check. . . . . . . . . . .6C-5
Hydraulic Pressure in P/S Circuit Check. . . .6C-6

Repair Instructions . . . . . . . . . . . ..6C-8

P/S Fluid Change . . . . . . . . . . . . 6C-8
P/S Fluid Level Check. . . . . . . . . . .6C-8
P/S Fluid Leakage Check. . . . . . . . . 6C-9
P/S System Air Bleeding Procedure . . . . ...6C-9
P/S Pump and A/C Compressor (If Equipped)

Drive Belt Inspection and Adjustment (M16A
Engine Model) . . . . . . . . . . . . .6C-10

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

Drive Belt Inspection and Adjustment (J20A
Engine Model) . . . . . . . . . . . . .6C-10