Fluid SUZUKI GRAND VITARA 2002 2.G Service Workshop Manual

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
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.

YH4
GRAND
VITARA
3
4
1. Reservoir cap
2. Cylinder
3. Piston assembly
4. Push rod
5. Piston stopper
6. Circlip
7. Boot
8. Lock nut
9. Clevis
1. Circlip
2. Push rod
3. Piston
4. Cylinder
1. Circlip
2. Push rod
3. Piston stopper
CLUTCH 7C1-7
DISASSEMBLY AND ASSEMBLY CLUTCH
MASTER CYLINDER
DISASSEMBLY
1) Remove boot and then circlip with piston pushed in.
2) Remove push rod and blow compressed air gradually into hole
for pipe connection to remove piston assembly, using care to
prevent it from jumping out.
INSPECTION
Inspect all disassembled parts for wear or damage and replace
parts if necessary.
NOTE:

Wash disassembled parts with brake fluid.

Do not reuse piston assembly and circlip.
Inspect cylinder bore for scoring or corrosion. It is best to replace
corroded cylinder. Corrosion can be identified as pits or excessive
roughness.
NOTE:
Polishing bore of cylinder with anything abrasive is prohib-
ited, as damage to cylinder bore may occur.
Rinse cylinder in clean brake fluid. Shake excess rinsing fluid from
cylinder. Do not use a cloth to dry cylinder, as lint from cloth cannot
be kept away from cylinder bore surfaces.
ASSEMBLY
NOTE:
Before installation, wash each part in specified brake fluid.
1) Apply brake fluid to inside of piston assembly and cylinder body.
2) Install piston assembly into cylinder.
3) With piston pushed down, install circlip as shown.
And install boot.

YH4
GRAND
VITARA
ªAº
1. Reservoir cap
2. Cylinder
3. Piston assembly
4. Push rod
5. Piston stopper
6. Circlip
7. Boot
8. Lock nut
9. Clevis
1. Clutch operating cylinder
2. Hose
3. E-ring
7C1-8 CLUTCH
4) Tighten lock nut to specified torque.
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
5) For installation of master cylinder to vehicle, refer to INSTALLA-
TION described previously.
CLUTCH OPERATING CYLINDER
REMOVAL
NOTE:
Do not allow fluid to get on painted surfaces.
1) Clean around reservoir cap and take out fluid with syringe or
such.
2) Disconnect fluid hose from operating cylinder.
3) Remove operating cylinder attaching bolts and operating cylin-
der.
INSTALLATION
1) For air bleeding of master cylinder alone, it must be removed
from vehicle.
For procedures of removal and installation of master cylinder as-
sembly and air bleeding, refer to CLUTCH MASTER CYLINDER
section.
2) Apply small amount of grease to rod tip.
ªAº: Grease 99000-25010
NOTE:
Don't allow any grease to be on boot.
3) Install clutch operating cylinder and torque attaching bolts to
specification.
4) Connect clutch fluid hose and torque union bolt to specification.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
(b): 23 N
.m (2.3 kg-m, 16.5 lb-ft)

YH4
GRAND
VITARA
CLUTCH 7C1-9
5) Fill reservoir with specified brake fluid and check for fluid leak-
age.
6) Bleed air from system and check clutch pedal free travel. Refer
to BRAKE section for air bleeding procedure.

YH4
GRAND
VITARA
7C1-14 CLUTCH
09917-58010 (G16 engine)
09923-73210
(J20 and H25 engines)
Bearing remover09923-36330 (G16 engine)
09923-36320
(J20 and H25 engines)
Clutch center guide09924-17810
Flywheel holder09925-98210
Input shaft bearing installer
TIGHTENING TORQUE SPECIFICATIONS
FasteningportionTightening torqueFastening ortionN.mkg-mlb-ft
Flare nut161.611.5
Master cylinder nut131.39.5
Lock nut101.07.5
Flywheel boltsG16 engine787.856.5Flywheel boltsJ20 and H25 engines707.050.5
Clutch cover bolts232.316.5
Operating cylinder bolt505.036.5
Clutch hose union bolt232.316.5
REQUIRED SERVICE MATERIALS
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium grease
SUZUKI SUPER GREASE A
(99000-25010)
Clutch master cylinder clevis pin.

Release fork.

Push rod tip of operating cylinder.
SUZUKI SUPER GREASE I
(99000-25210)Input shaft spline front end.
Clutch fluid
(Brake fluid)DOT3 or SAE J1703

Clutch reservoir.

Clutch master cylinder.

Clutch operating cylinder.
SealantSUZUKI BOND No.1215
(99000-31110)Flywheel bolts
SPECIAL TOOLS

YH4
GRAND
VITARA
1. To door switch (driver side) B / Bl
2. To transmission range switch G / Bl
(A / T vehicle only, if equipped) L
3. To transmission range switch G / O
(A / T vehicle only, if equipped) 2
4. To transmission range switch Y / G
(A / T vehicle only, if equipped) D
5. To transmission range switch O / Bl
(A / T vehicle only, if equipped) N
6. To transmission range switch O / G
(A / T vehicle only, if equipped) P
7. To transmission range switch R
(A / T vehicle only, if equipped) R
8. To ground B
9. To PCM (A / T vehicle only) W / B
10. To ECT sensor Y / W
11. To fuel level gauge Bl / W
12. To ground B / Y
13. To combination switch G / Y
NOTE:
Terminal arrangement of coupler viewed from harness side.
Coupler A Coupler B Coupler C
Coupler A Coupler B Coupler C
1. Blank ÐÐ
2. Blank ÐÐ
3. To ignition switch B / W
4. Blank ÐÐ
5. To ABS control module Bl / O
(if equipped)
6. To PCM (A / T vehicle only) Gr / Bl
7. To ABS control module Br
(if equipped)
8. To VSS Bl / Y
9. To combination switch G / R
10. To SDM (if equipped) Y / G or Bl
11. To main fuse W / Bl
12. To fuse box W
13. To combination switch R
14. To ECM (PCM for A / T vehicle) V
(if equipped)
15. To ECM (PCM for A / T vehicle) V / Y
16. To ECM (PCM for A / T vehicle) O / B
(if equipped)1. To ground B
2. To ECM (PCM for A / T vehicle) Br
3. To ignition switch (if equipped) V / R
4. To brake fluid level switch R / B
5. To parking brake switch V
6. To seat belt switch (if equipped) Gr / R
7. To generator W / R
8. To oil pressure switch Y / B
9. To combination switch R / Y
10. To ignition switch (if equipped) Bl / R or CHECK
or ENGINE
or ABSif equipped
if equippedif equipped
INSTRUMENTATION / DRIVER INFORMATION 8C-3