Suzuki Grand Vitara JB419. Service manual - part 115

 

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Suzuki Grand Vitara JB419. Service manual - part 115

 

 

Clutch: 5C-2

Component Location

Clutch Fluid Pipe and Hose Location

S5JB0B5303001

Repair Instructions

Air Bleeding of Clutch System

S5JB0B5306014

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 in related manual” for air 
bleeding procedure.

1

1

2

2

2

3

4

5

5

6

6

7

[A]

I5JB0A530002-03

[A]: Right-hand steering vehicle

3. Clutch fluid hose

6. Brake master cylinder reservoir

1. Clutch master cylinder

4. Clutch operating cylinder assembly

7. Clutch fluid pipe joint

2. Clutch fluid pipe

5. Clutch reservoir hose

3

1

2

4

I5JB0A530017-01

5C-3 Clutch: 

Clutch Master Cylinder Removal and 
Installation

S5JB0B5306005

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 “Air Bleeding 
of Clutch System”
 for air bleeding procedure.

1

2

3

4

3

6

5

I5JB0A530013-01

1, “A”

2, (a)

2, (a)

I5JB0A530014-01

I5JB0A530015-03

Clutch: 5C-4

Clutch Operating Cylinder Assembly Removal 
and Installation

S5JB0B5306007

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.

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 Clutch System” fo
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.

3

1

2

4

I5JB0A530017-01

3

1, (b)

2

4

(a)

I5JB0A530018-01

I5JB0A530015-03

5C-5 Clutch: 

Clutch Cover, Clutch Disc and Flywheel Components

S5JB0B5306008

Clutch Cover, Clutch Disc and Flywheel 
Removal and Installation

S5JB0B5306009

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.

I5JB0A530022-01

1. Input shaft bearing

4. Clutch cover

: 20 N

⋅m (2.0 kgf-m, 14.5 lb-ft)

2. Flywheel

5. Clutch cover bolt

: 65 N

⋅m (6.5 kgf-m, 47.0 lb-ft)

3. Clutch disc

6. Flywheel bolt

: Do not reuse.

IYSQ01530019-01

I2RH01530023-01

 

 

 

 

 

 

 

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