2006 SUZUKI SWIFT engine cover

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-7
Clutch Operating Cylinder Removal and
Installation
S7RS0B5306010
Removal1) Clean around brake master cylinder reservoir cap and take out fluid with syringe or such from brake
master cylinder reservoir.
2) Disconnect clutch fluid pipe (2) from operating cylinder referring to “Clutch Fluid Pipe Removal and
Installation”.
3) Remove clutch operating cylinder (1).
Installation
Reverse removal procedure for installation noting the
following. • Apply grease to push rod tip.
“A”: Grease 99000–25100 (SUZUKI Silicone
Grease)
• Tighten clutch operating cylinder bolt to specified torque.
Tightening torque
Clutch operating cylinder bolt: 23 N·m (2.3 kgf-
m, 17.0 lb-ft)
Clutch Operating Cylinder InspectionS7RS0B5306011
Check operating cylinder for damage and fluid leakage.
If malfunction is found, repl ace clutch operating cylinder.
Clutch Pedal and Clutch Pedal Bracket ComponentsS7RS0B5306012
2
1I4RS0A530010-01
“A”
I4RS0A530011-01
I6RS0C530005-01
1. Clutch pedal bracket 9. Pedal pad
2. Pedal bracket nut 10. Cushion
3. Pedal bracket bolt : Pedal bracket bolt must be tighten after pedal bracket nut. 11. Return spring
: Apply grease 99000-25011 to inside of spring.
4. Pedal shaft bolt 12. Pedal cover plate
5. Pedal bush : Apply grease 9900-25011 to outside of bush. 13. Pedal plate cushion
6. Pedal shaft spacer : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
7. Pedal shaft nut : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 5C-8 Clutch:
Clutch Cover, Clutch Disc and Flywheel ComponentsS7RS0B5306013
Clutch Cover, Clutch Disc and Flywheel
Removal and Installation
S7RS0B5306014
Removal1) Dismount manual transaxle assembly referring to “Manual Transaxle Unit Dismounting and
Remounting in Section 5B”.
2) Hold flywheel with specia l tool and remove clutch
cover bolts (1), clutch cover (2) and clutch disc.
Special tool
(A): 09924–17811
8. Clutch pedal : Apply grease 99000-25011 to outside surface of pin.
(a)
(b)
(b)
A
A
A
12
115
6
A3
A4
710
2
98
1
I4RS0A530013-02
1. Flywheel 9. Clutch disc
2. Flywheel bolt 10. Clutch cover bolt
3. Clutch release shaft seal : Apply grease 99000-25011 to seal lip. 11. Release arm
4. Clutch release shaft No.2 bush : Apply grease 99000-25011 to bush inside. 12. Release arm bolt
5. Clutch release shaft : Apply grease 99000-25011 to the end of release shaft arm. :70 N
⋅m (7.0 kgf-m, 51.0 lb-ft)
6. Clutch release shaft No.1 bush : Apply grease 99000-25011 to bush inside. :23 N
⋅m (2.3 kgf-m, 17.0 lb-ft)
7. Release bearing : Apply grease 99000-25011 to joint of bearing and release shaft and also bearing inside. Do not reuse.
8. Clutch cover
I4RS0A530014-01

Downloaded from www.Manualslib.com manuals search engine 5C-10 Clutch:
3) Aligning clutch disc to flywheel center using special
tool, install clutch cover (1) and bolts (2). Then
tighten bolts (2) to specification.
NOTE
• While tightening clutch cover bolts, compress clutch disc with special tool
(clutch center guide) by hand so that disc
is centered.
• Tighten cover bolts little by little evenly in diagonal order.

Special tool
(A): 09924–17811
(B): 09923–36320
Tightening torque
Clutch cover bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-
ft)
4) Slightly apply grease to input shaft (1), then join manual transaxle assembly with engine referring to
“Manual Transaxle Unit Dismounting and
Remounting in Section 5B”.
“A”: Grease 99000–25210 (SUZUKI Super
Grease I)
NOTE
When inserting transaxle input shaft to clutch
disc, turn crankshaft li ttle by little to match
the splines.

Clutch Cover, Clutch Disc and Flywheel
Inspection
S7RS0B5306015
Input Shaft Bearing
Check bearing (1) for smooth ro tation 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 hav e reached service limit at
any of rivet holes (2), repl ace clutch disc assembly (1).
Rivet head depth
Standard: 1.65 – 2.25 mm (0.06 – 0.09 in.)
Limit: 0.5 mm (0.02 in.)
I4RS0A530017-01
I4RS0A530018-01
I3RM0A530014-01
I4RS0A530019-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-11
Clutch Cover1) Check diaphragm spring (1) for abnormal wear or damage.
2) Inspect pressure plate (2) for wear or heat spots.
3) If abnormality is found, replace clutch cover. Do not disassemble it into diaphragm spring and
pressure plate.
Flywheel
Check surface contacting clutch disc for abnormal wear
or heat spots. Replace or repair as required.
Clutch Release System Removal and
Installation
S7RS0B5306016
Removal 1) Remove release arm by loosening its bolt.
2) Take out release bearing by turning release shaft (1).
3) Drive out No.2 bush usin g special tool and hammer.
Release shaft seal will also be pushed out.
Special tool
(A): 09922–46010
4) Remove release shaft (1). 5) Install tap (M16 X 1.5) (1) to clutch release shaft
No.1 bush.
6) Pull No.1 bush out using tap (1) and special tools. Special tool
(B): 09923–46020
(C): 09930–30104
Installation 1) Drive in a new No.1 bush using special tools and
hammer, and then apply grease to bush inside.
Special tool
(A): 09943–88211
(B): 09923–46030
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
I3RM0A530015-01
I4RS0A530020-01
IYSY01531016-01
IYSY01531017-01
I3RM0A530016-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-13
Clutch Release System InspectionS7RS0B5306017
Clutch Release Bearing
Check clutch release bearing for smooth rotation. If
abnormality is found, replace it.
CAUTION!
Do not wash release bearing. Washing may
cause grease leakage and consequential
bearing damage.

Clutch Release Shaft
Check clutch release shaft and its pin for deflection or
damage.
If abnormality is found, replace it.
Specifications
Tightening Torque SpecificationsS7RS0B5307001
NOTE
The specified tightening torque is also described in the following.
“Clutch Fluid Pipe and Hose Components”
“Clutch Pedal and Clutch Pedal Bracket Components”
“Clutch Cover, Clutch Disc and Flywheel Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
I3RM0A530020-01
I3RM0A530021-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
CPP switch lock nut 7.5 0.75 5.5 )
Clutch operating cylinder bolt 23 2.3 17.0 )
Flywheel bolt 70 7.0 51.0 )
Clutch cover bolt 23 2.3 17.0 )
Release lever bolt 23 2.3 17.0 )

Downloaded from www.Manualslib.com manuals search engine 5C-14 Clutch:
Special Tools and Equipment
Recommended Service MaterialS7RS0B5308001
NOTE
Required service material is also described in the following.
“Clutch Fluid Pipe and Hose Components”
“Clutch Pedal and Clutch Pedal Bracket Components”
“Clutch Cover, Clutch Disc and Flywheel Components”

Special ToolS7RS0B5308002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011) / ) / ) / )
SUZUKI Silicone Grease P/No.: 99000–25100) / )
SUZUKI Super Grease I P/No.: 99000–25210) / )
09921–26020 09922–46010
Bearing remover Clutch bush remover
)) / )
09923–36320 09923–46020
Clutch center guide (15 mm) Joint pipe
))
09923–46030 09924–17811
Joint pipe Flywheel holder
)) / ) / ) / )
09925–98210 09925–98221
Input shaft bearing inst aller Bearing installer
))
09930–30104 09943–88211
Sliding shaft Pinion bearing installer
) / ))

Downloaded from www.Manualslib.com manuals search engine 6B-3 Steering Wheel and Column:
Repair Instructions
Steering Wheel and Column ConstructionS7RS0B6206001
21
2 3
4
7
5
6
8
9
11
12 10
15
(a)
(b)
13(c)
14
(d)
16
I4RS0B620001-04
1. Driver air bag (inflator) module
8. Steering column lower cover 15. Audio control switch
2. Steering wheel 9. Steering column 16. Knee protector plate
3. Driver air bag (inflator) module mounting bolt 10. Steering lock assembly (ignition switch) : 9 N⋅m (0.9 kgf-m, 6.5 lb-ft)
4. Steering wheel nut 11. Steering lower shaft : 33 N⋅m (3.3 kgf-m, 24 lb-ft)
5. Contact coil cable assembly 12. Steering joint cover : 25 N⋅m (2.5 kgf-m, 18 lb-ft)
6. Wiper switch and lighting switch 13. Upper and lower joint bolt
: After tightening lower joint bolt, tighten upper joint bolt. : 14 N
⋅m (1.4 kgf-m, 10.5 lb-ft)
7. Steering column upper cover 14. Steering column mounting nut
: After tightening lower nut, tighten upper nut.

Downloaded from www.Manualslib.com manuals search engine 6B-5 Steering Wheel and Column:
Contact Coil Cable Assembly Removal and
Installation
S7RS0B6206003
CAUTION!
Do not turn contact coil more than allowable
number of turns (about two and a half turns
from the center position clockwise or
counterclockwise respectively), or coil will
break.

Removal
1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Remove steering wheel from steering column referring to “Steering Wheel Removal and
Installation”.
4) Remove steering column lower cover (2) and upper cover (1).
5) Remove contact coil cable assembly (1) from steering column. Installation
1) Check to make sure that vehicle’s front tires are set
at straight-ahead position and then ignition switch is
at LOCK position.
2) Install contact coil cable assembly to steering column securely.
NOTE
New contact coil cable assembly is supplied
with contact coil set and held at its center
position with a lock pin (1). Remove this lock
pin after installing contact coil cable
assembly to steering column.

3) Install steering column upper cover (1) and lower cover (2).
4) Install steering wheel to steering column. Refer to
“Steering Wheel Removal and Installation”.
5) Connect battery negative (–) cable.
6) Enable air bag system refe rring to “Enabling Air Bag
System in Section 8B”.
2
1
I4RS0B620002-04
1I6RS0B620001-01
I4RS0A620010-01
2
1
I4RS0B620002-04