Suzuki Grand Vitara JB416 / JB420. Manual — part 261
5C-8 Clutch:
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
S5JB0A5306010
3
1, (b)
2
4
(a)
I5JB0A530018-01
I5JB0A530015-03
I5JB0A530022-01
1. Input shaft bearing
4. Clutch cover
: 23 N
⋅m (2.3 kgf-m, 17.0 lb-ft)
2. Flywheel
5. Clutch cover bolt
: 70 N
⋅m (7.0 kgf-m, 50.5 lb-ft) (for M16 engine model)
68.5 N
⋅m (6.85 kgf-m, 49.5 lb-ft) (for J20 engine model)
3. Clutch disc
6. Flywheel bolt
: Do not reuse.
Clutch: 5C-9
Clutch Cover, Clutch Disc and Flywheel
Removal and Installation
S5JB0A5306012
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 (for M16 engine model) (a): 70 N·m
(7.0 kgf-m, 50.5 lb-ft)
Flywheel bolt (for J20 engine model) (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
IYSQ01530019-01
I2RH01530023-01
I5JB0A530020-01
IYSQ01530022-01
5C-10 Clutch:
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
S5JB0A5306013
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
Clutch: 5C-11
Specifications
Tightening Torque Specifications
S5JB0A5307001
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
S5JB0A5308001
Special Tool
S5JB0A5308002
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 (for M16 engine model)
70
7.0
50.5
Flywheel bolt (for J20 engine model)
68.5
6.9
49.5
Clutch cover bolt
23
2.3
17.0
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
)
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