Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 357

5C-3 Clutch: 

Diagnostic Information and Procedures

Clutch (Hydraulic Type) Symptom Diagnosis

S6JB0A5304001

Condition

Possible cause

Correction / Reference Item

Slipping

Improper clutch pedal free travel

Bleed air or replace master cylinder.

Worn or oily clutch disc facing

Replace disc.

Warped disc, pressure plate or flywheel 
surface

Replace disc, clutch cover or flywheel.

Weakened diaphragm spring

Replace clutch cover.

Master cylinder piston or seal cup not 
returning

Repair master cylinder.

Dragging clutch

Improper clutch pedal free travel

Bleed air or replace master cylinder.

Weakened diaphragm spring, or worn 
spring tip

Replace clutch cover.

Rusted input shaft splines

Lubricate.

Damaged or worn splines of 
transmission input shaft

Replace input shaft.

Excessively wobbly clutch disc

Replace disc.

Clutch facings broken or dirty with oil

Replace disc.

Fluid leakage

Repair or replace.

Clutch vibration

Glazed (glass-like) clutch facings

Repair or replace disc.

Clutch facings dirty with oil

Replace disc.

Release bearing slides unsmoothly

Replace clutch operating cylinder assembly.

Wobbly clutch disc, or poor facing 
contact

Replace disc.

Weakened torsion springs in clutch disc Replace disc.
Clutch disc rivets loose

Replace disc.

Distorted pressure plate or flywheel 
surface

Replace clutch cover or flywheel.

Weakened or loosened engine mounting 
bolt or nut

Retighten or replace mounting.

Noisy clutch

Worn or broken release bearing

Replace clutch operating cylinder assembly.

Input shaft front bearing worn down

Replace input shaft bearing.

Excessive rattle of clutch disc hub

Replace disc.

Cracked clutch disc

Replace disc.

Pressure plate and diaphragm spring 
rattling

Replace clutch cover.

Grabbing clutch

Clutch disc facings soaked with oil

Replace disc.

Clutch disc facings excessively worn

Replace disc.

Rivet heads showing out of facing

Replace disc.

Weakened torsion springs

Replace disc.

Clutch: 5C-4

Repair Instructions

Clutch Pedal Height Inspection

S6JB0A5306012

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

S6JB0A5306013

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

S6JB0A5306014

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

Clutch fluid
: Refer to reservoir cap.

Air Bleeding of Clutch System

S6JB0A5306015

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.

1. Clutch pedal

3

2

1

“a”

I5JB0A530003-01

1

“a”

I5JB0A530004-01

I5JB0A530015-03

5C-5 Clutch: 

Clutch Pedal Position (CPP) Switch Removal 
and Installation

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Removal

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

switch OFF.

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

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

S6JB0A5306002

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.)

I5JB0A530005-02

I5JB0A530006-01

1

1

2

“a”

I6JB0A530001-01

Clutch: 5C-6

Clutch Fluid Pipe and Hose Removal and 
Installation

S6JB0A5306003

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).

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

S6JB0A5306004

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

1

2

3

I5JB0A530008-01

1

2

3

4

I5JB0A530009-03

1

3

2

I5JB0A530010-02

1

3, (a)

4, (b)

2

I5JB0A530011-03

2

1

2

I5JB0A530012-03