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
)