Suzuki Grand Vitara JB416 / JB420. Manual — part 260

5C-4 Clutch:

Repair Instructions

Clutch Pedal Height Inspection

S5JB0A5306014

Measure clutch pedal height “a” from brake pedal (2). If
pedal height is excessive low or high, check installation
position of clutch position switch, clutch fluid leakage,
bending of clutch pedal arm and bending of push rod of
clutch master cylinder (3). If any abnormality is found,
adjust or replace it with a new one.

Clutch pedal height
“a”: Approx. 20 mm (0.79 in.)

Clutch Pedal Free Travel Check

S5JB0A5306015

Depress clutch pedal (1), stop the moment clutch
resistance is felt and measure distance (clutch pedal
free travel). Free travel should be within the following
specification. If free travel is out of specification, check
installation position of clutch pedal position switch, clutch
fluid leakage, bending of clutch pedal arm and bending
of push rod of clutch master cylinder. If any abnormality
is found, adjust or replace it with a new one.

Clutch pedal free travel “a”
: 0 – 10 mm (0 – 0.4 in.)

Clutch Fluid Inspection

S5JB0A5306016

Refer to “Brake Fluid Level Check in Section 4A”.

Clutch fluid
: Refer to reservoir cap.

Air Bleeding of Clutch System

S5JB0A5306017

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” for air bleeding procedure.

Clutch Pedal Position (CPP) Switch Removal
and Installation

S5JB0A5306001

Removal

1) Disconnect connector of CPP switch (1) with ignition

switch OFF.

2) Remove CPP switch (1) from pedal bracket.

1. Clutch pedal

3

2

1

“a”

I5JB0A530003-01

1

“a”

I5JB0A530004-01

I5JB0A530015-03

I5JB0A530005-02

Clutch: 5C-5

Installation

1) Instal CPP switch to pedal bracket.
2) Adjust switch position referring to “Clutch Pedal

Position (CPP) Switch Inspection and Adjustment”.

3) Connect connector to CPP switch securely.

Clutch Pedal Position (CPP) Switch Inspection
and Adjustment

S5JB0A5306002

Inspection
Check for resistance between terminals under each
condition below. If check result is not satisfactory,
replace.

CPP switch resistance
When switch shaft is pushed (1): Continuity
When switch shaft is free (2): No continuity

Adjustment
With clutch pedal (1) released, adjust switch (2) position
so that clearance between end of thread and clutch
pedal arm is within specification.

Clearance between end of thread and clutch pedal
arm
“a”: 0.5 – 1.5 mm (0.02 – 0.06 in.)

Clutch Fluid Pipe and Hose Removal and
Installation

S5JB0A5306003

CAUTION

!

Do not allow fluid to get on painted surface. It
may cause painted surface damage.

Removal

1) Remove dust and dirt from each joint of hose and

pipe to be disconnected and clean around reservoir
cap of brake master cylinder.

2) Take out fluid with syringe or such.
3) Remove clamp (1) of clutch master cylinder (2) and

disconnect fluid pipe (3).

4) Disconnect fluid pipe (1) from hose (2).

NOTE
To disconnect pipe (1) from hose (2),
separate them by using flare nut wrench (4)
and spanner (3) so as not to kink them.

5) Pull clamp (1) of fluid pipe joint (2) and disconnect

fluid hose (3).

I5JB0A530006-01

1

1

2

3

“a”

I5JB0A530007-02

1

2

3

I5JB0A530008-01

1

2

3

4

I5JB0A530009-03

1

3

2

I5JB0A530010-02

5C-6 Clutch:

Installation
Reverse removal sequence noting the following points.
• Tighten flare nut (3) and hose bracket nut (4) to

specified torque.

Tightening torque
Clutch fluid pipe flare nut (a): 16 N·m (1.6 kgf-m,
11.5 lb-ft)
Clutch fluid hose bracket nut (b): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)

• Do not allow pipe (1) and hose (2) to contact hard

against vehicle or other parts.

• Install each clamp securely.
• After installation, check clutch pedal free travel and

bleed air from system.

• Check fluid leakage.
• Add fluid close to MAX level of reservoir.

Clutch Fluid Pipe and Hose Inspection

S5JB0A5306004

Check pipe (1) and hose (2) for dent, kink, crack, dirt and
dust. Replace if check result is not satisfactory.

Clutch Master Cylinder Removal and
Installation

S5JB0A5306005

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.

1

3, (a)

4, (b)

2

I5JB0A530011-03

2

1

2

I5JB0A530012-03

1

2

3

4

3

6

5

I5JB0A530013-01

Clutch: 5C-7

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

S5JB0A5306008

• 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

S5JB0A5306009

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)

I5JB0A530014-01

I5JB0A530015-03

“b”

“a”

1

I5JB0A530016-01

3

1

2

4

I5JB0A530017-01