cylinder SUZUKI GRAND VITARA 2000 2.G Service Repair Manual

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-33
1. ABS hydraulic unit /
control module
assembly
2. Nut
1. To left-front
2. To right-front
3. To rear
4. From master cylinder4) Remove three nuts and take out ABS hydraulic unit / control
module assembly from bracket.
CAUTION:

Do not give an impact to hydraulic unit.

Use care not to allow dust to enter hydraulic unit.

Do not place hydraulic unit on its side or upside down.
Handling it in inappropriate way will affect its original
performance.
INSTALLATION
1) Install hydraulic unit by reversing removal procedure.
Tightening Torque
(a): 16 N
.m (1.6 kg-m, 12.0 lb-ft)
(b): 21 N
.m (2.1 kg-m, 15.5 lb-ft)
(c): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
2) Bleed air from brake system. Refer to ªBLEEDING BRAKESº in
Section 5.
3) Check each installed part for fluid leakage and perform hydraulic
unit operation check.

YH4
GRAND
VITARA
1. Transmission
2. Breather clamp
3. Breather hose
4. Wiring harness clamp
5. Intake manifold
MANUAL TRANSMISSION (TYPE 1) 7A-9
DISMOUNTING OF TRANS. UNIT
IN CABIN
Remove transmission shift control lever (refer to page 7A-4) and
transfer shift control lever knob.
IN ENGINE ROOM
1) Disconnect negative (±) cable of battery.
2) Remove breather hose from clamp at the rear end of cylinder
head.
3) Remove starting motor fixing bolts and nut and then remove
starter.
4) Remove transmission fastening bolts.

YH4
GRAND
VITARA
1. Match mark
1. Flange bolt
2. Front propeller shaft
1. Transmission jack
2. Engine rear mounting member
7A-10 MANUAL TRANSMISSION (TYPE 1)
ON LIFT
1) Drain oil from transmission and transfer.
2) Give match marks on joint flange and propeller shaft as shown
in figure. (front and rear)
3) Remove flange bolts of rear propeller shaft universal joint and
pull out propeller shaft.
4) Remove flange bolts of front propeller shaft universal joint and
pull out propeller shaft.
5) Remove clutch operating cylinder from transmission. It is not
necessary to disconnect clutch hose from operating cylinder.
NOTE:

It is not necessary to drain transmission oil when dis-
mounting transmission and transfer for clutch mainte-
nance only.

Work without draining transfer oil is possible if front pro-
peller shaft is dismounted together with transmission and
transfer.
6) Remove clutch housing lower plate.
7) Disconnect couplers from 4WD switch, back up light switch and
speed sensor assembly and release their harness from clamps.
Remove nuts from joint with engine.
8) Apply transmission jack and remove engine rear mounting
member taking off its bolts.
9) After removing mounting member, move rearward transmission
and transfer assemblies placed on jack and then lower them.

YH4
GRAND
VITARA
1. Match mark
7A-12 MANUAL TRANSMISSION (TYPE 1)
REMOUNTING OF TRANS. UNIT
For remounting, reverse dismounting procedure.
Use specified torques as given below.
Tightening Torque
(a): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
(b): 50 N
.m (5.0 kg-m, 36.5 lb-ft)

For tightening torque of transmission stiffener bolt, refer to
ªENGINE MECHANICALº section.

Set each clamp for wiring, hose and cable securely.

Set clamp for shift control lever boots securely.

After installing clutch operating cylinder, check clutch pedal free
travel. Refer to SECTION 7C1 ªCLUTCHº.

Fill gear oil to transmission and transfer as specified.

Connect battery and check function of engine, clutch and trans.

When installing propeller shaft, align the match marks.

YH4
GRAND
VITARA
7C1
CLUTCH 7C1-1
GENERAL DESCRIPTION7C1 - 2 . . . . . . . . . . . . .
DIAGNOSIS7C1 - 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7C1 - 4 . . . . . . . . . . . . . . .
Clutch Pedal Height 7C1 - 4. . . . . . . . . . . . . . . . . .
Clutch Pedal Free Travel 7C1 - 4. . . . . . . . . . . . .
Clutch Fluid Pipe and Hose 7C1 - 4. . . . . . . . . . .
Clutch Master Cylinder 7C1 - 5. . . . . . . . . . . . . . .
Fluid Inspection 7C1 - 6. . . . . . . . . . . . . . . . . . . . .
Disassembly and Assembly
Clutch Master Cylinder 7C1 - 7. . . . . . . . . . . . . . Clutch Operating Cylinder 7C1 - 8. . . . . . . . . . . .
UNIT REPAIR7C1-10 . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Cover, Clutch Disc and
Flywheel 7C1 - 10. . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS7C1-14 . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7C1-14 . . . . .
SPECIAL TOOLS7C1-14 . . . . . . . . . . . . . . . . . . . . .
SECTION 7C1
CLUTCH
CONTENTS

YH4
GRAND
VITARA
1. Crankshaft
2. Flywheel
3. Clutch disc
4. Pressure plate
5. Clutch cover
6. Diaphragm spring
7. Release bearing
8. Input shaft bearing
9. Input shaft
10. Operating cylinder
11. Clutch housing
12. Release fork
7C1-2 CLUTCH
The clutch is a diaphragm-spring clutch of a dry single
disc type. The diaphragm spring is of a tapering-finger
type, which is a solid ring in the outer diameter part,
with a series of tapered fingers pointing inward.
The disc, carrying torsional coil springs, is positioned
on the transmission input shaft with an involute spline
fit.
The clutch cover is secured to the flywheel, and car-
ries the diaphragm spring in such a way that the pe-
ripheral edge part of the spring pushes on the pres-
sure plate against the flywheel (with the disc in be-
tween), when the clutch release bearing is held back.
This is the engaged condition of the clutch.Depressing the clutch pedal causes the release bear-
ing to advance and pushes on the tips of the tapered
fingers of the diaphragm spring. When this happens,
the diaphragm spring pulls the pressure plate away
from the flywheel, thereby interrupting the flow of
drive from flywheel through clutch disc to transmis-
sion input shaft.
GENERAL DESCRIPTION

YH4
GRAND
VITARA
CLUTCH 7C1-3
DIAGNOSIS
ConditionPossible CauseCorrection
Slipping
Improper clutch pedal free travel.

Worn or oily clutch disc facing.

Warped disc, pressure plate or flywheel
surface.

Weakened diaphragm spring.

Master cylinder piston or seal cup not returning.Bleed air or replace master
cylinder.
Replace disc.
Replace disc, clutch cover or
flywheel.
Replace clutch cover.
Repair master cylinder.
Dragging clutch
Improper clutch pedal free travel.

Weakened diaphragm spring, or worn spring tip.

Rusted input shaft splines.

Damaged or worn splines of transmission
input shaft.

Excessively wobbly clutch disc.

Clutch facings broken or dirty with oil.

Fluid leakage.Bleed air or replace master
cylinder.
Replace clutch cover.
Lubricate.
Replace input shaft.
Replace disc.
Replace disc.
Repair or replace.
Clutch vibration
Glazed (glass-like) clutch facings.

Clutch facings dirty with oil.

Release bearing slides unsmoothly on input
shaft bearing retainer.

Wobbly clutch disc, or poor facing contact.

Weakened torsion springs in clutch disc.

Clutch disc rivets loose.

Distorted pressure plate or flywheel surface.

Weakened or loosened engine mounting
bolt or nut.Repair or replace disc.
Replace disc.
Lubricate or replace input
shaft bearing retainer.
Replace disc.
Replace disc.
Replace disc.
Replace clutch cover or flywheel.
Retighten or replace mounting.
Noisy clutch
Worn or broken release bearing.

Input shaft front bearing worn down.

Excessive rattle of clutch disc hub.

Cracked clutch disc.

Pressure plate and diaphragm spring rattling.Replace release bearing.
Replace input shaft bearing.
Replace disc.
Replace disc.
Replace clutch cover.
Grabbing clutch
Clutch disc facings soaked with oil.

Clutch disc facings excessively worn.

Rivet heads showing out of facing.

Weakened torsion springs.Replace disc.
Replace disc.
Replace disc.
Replace disc.

YH4
GRAND
VITARA
1. Clutch pedal
2. Clevis lock nut
3. Push rod
1. Clutch master cylinder
2. Clutch pipe
3. Clutch hose
4. Clutch operating cylinder
1. Pipe
2. Hose
3. Spanner
4. Flare nut wrench2, (a)
7C1-4 CLUTCH
ON-VEHICLE SERVICE
CLUTCH PEDAL HEIGHT
Adjust clutch pedal height by loosening clevis lock nut and turning
push rod as shown.
Clutch pedal height is normal if clutch pedal is about
20 mm (0.79 in.) higher than brake pedal.
After adjusting, tighten lock nut to specified torque.
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
CLUTCH PEDAL FREE TRAVEL
Depress clutch pedal, stop the moment clutch resistance is felt and
measure distance (clutch pedal free travel). Free travel should be
within following specification.
Pedal free travel ªaº: 15 ± 25 mm (0.6 ± 1.1 in.)
CLUTCH FLUID PIPE AND HOSE
REMOVAL
NOTE:
Do not allow fluid to get on painted surface.
1) Remove dust and dirt from each joint of hose and pipe to be dis-
connected and clean around reservoir cap.
2) Take out fluid with syringe or such.
3) Disconnect fluid pipe from hose.
NOTE:
To disconnect pipe from hose, separate them by using flare
nut wrench and spanner so as not to kink them.

YH4
GRAND
VITARA
1. Pipe
2. Hose
3. Flare nut
1. Pipe
2. Hose
3. Flare nut
4. E-ring
1. Master cylinder
assembly
2. Clutch pipe
3. Attaching nut
4. Attaching bolt
5. Clevis pin
6. Clip
7. Flare nut
CLUTCH 7C1-5
INSPECTION
Check pipe and hose for dent, kink, crack, dirt and dust. Replace
if check result is not satisfactory.
INSTALLATION
Reverse removal sequence noting following points.
Tighten flare nuts to specified torque.
Tightening Torque
(a): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
NOTE:

For air bleeding of master cylinder alone, it must be removed
from vehicle.
(For procedures of removal and installation of master cylin-
der assembly and air bleeding, refer to CLUTCH MASTER
CYLINDER section.)

Do not allow fluid to get on painted surface.

Do not allow pipe and hose to contact hard against vehicle
or other parts.

Install each clamp securely.

Install E-ring securely as shown.

After installation, check clutch pedal free travel and bleed air
from system.

Check fluid leakage.

Add fluid close to MAX level of reservoir.
CLUTCH MASTER CYLINDER
REMOVAL
1) Clean around reservoir cap and take out fluid with syringe or
such.
2) Remove push rod clevis pin.
3) Disconnect fluid pipe from master cylinder.
NOTE:
Do not allow fluid to get on painted surfaces.
4) Remove master cylinder attaching nut and bolt.
5) Remove master cylinder assembly and gasket.

YH4
GRAND
VITARA
1. Master cylinder
1. Attaching bolt
2. Attaching nut
3. Clevis pin
ªAº
7C1-6 CLUTCH
INSTALLATION
1) To bleed air from master cylinder itself, tilt it as shown in figure
and add fluid into it.
NOTE:
After bleeding air from master cylinder, plug pipe hole in it
to prevent fluid from spilling out of it till pipe is connected.
2) Install master cylinder assembly and new gasket to body, attach-
ing bolt, nuts and push rod clevis pin.
NOTE:
Do not reuse gasket.
3) Torque attaching bolt and nut to specification.
4) Connect fluid pipe and torque flare nut to specification.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
(b): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
5) Apply grease to clevis pin and install it.
ªAº: Grease 99000-25010
6) Fill reservoir with specified brake fluid and check fluid leakage.
7) After installation, bleed air from system and check clutch pedal
free travel. Refer to BRAKE section for air bleeding procedure.
FLUID INSPECTION
Fluid level should be always between MIN and MAX lines on reser-
voir. If fluid decreases quickly, check for leakage, repair leaky point,
if any, and add fluid up to MAX level.
NOTE:

Brake fluid damages painted surface badly. Should it get on
painted surface, remove it immediately and clean surface
thoroughly.

Do not use shock absorber fluid or any other fluid which con-
tains mineral oil. Do not use container which has been used
for mineral oil or which is wet from water. Mineral oil will
cause swelling and distortion of rubber parts in hydraulic
clutch system and water will mix with brake fluid, lowering
fluid boiling point. Keep all fluid containers capped to pre-
vent contamination.

Make sure not to use fluid whose container cap was first
opened more than a year ago.