2006 SUZUKI SX4 Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-4
Clutch Fluid Pipe and Hose LocationS6RW0D5306004
Clutch Fluid Pipe Removal and InstallationS6RW0D5306005
Removal
CAUTION!
Do not allow fluid to get on painted surface. It
may cause painted surface damage.

1) Remove dust and dirt from each joint of pipe to be
disconnected and clean around brake master
cylinder reservoir cap.
2) Take out fluid with syringe or such from brake master
cylinder reservoir.
3) Pull clamp (1) of clutch master cylinder (3) and pull
clamp (5) of fluid pipe joint (4), and then disconnect
clutch fluid pipe (2).
4) Pull clamp (6) of damper (7), and then disconnect
damper (7) from clutch fluid pipe (2).Installation
Reverse removal procedure for installation noting the
following.
CAUTION!
• Do not allow fluid to get on painted
surface.
• Do not allow pipe to contact hard against
vehicle body or other parts.

• Install each clamp securely.
• After installation, check clutch pedal free travel and
bleed air from clutch system referring to “Clutch Pedal
Inspection” and “Air Bleeding of Clutch System”.
• Check fluid leakage.
• Add fluid to MAX level of reservoir.
Clutch Fluid Pipe InspectionS6RW0D5306006
Check pipe (1) for damage, dirt and leak. Replace if
check result is not satisfactory.
4 [A]
3131
22
4
I5RW0A530003-02
[A]: RH steering vehicle 3. Clutch reservoir hose
1. Clutch master cylinder 4. Brake master cylinder reservoir
2. Clutch fluid pipe
2
6
5 74
3
1
2
I5RW0B530002-03
[A]: LH steering vehicle
[B]: RH steering vehicle
I5RW0A530005-01

Downloaded from www.Manualslib.com manuals search engine 5C-5 Clutch:
Clutch Master Cylinder Removal and
Installation
S6RW0D5306007
Removal
1) 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 (4) from clutch master
cylinder (1) referring to “Clutch Fluid Pipe Removal
and Installation”.
3) Disconnect clutch reservoir hose (2).
4) Remove push rod from clutch pedal, and then
remove clutch master cylinder.
Installation
Reverse removal procedure for installation noting the
following.
• Apply grease to push rod tip.
“A”: Grease 99000–25100 (SUZUKI Silicone
Grease)
• Tighten clutch master cylinder nut to specified torque.
Tightening torque
Clutch master cylinder nut: 13 N·m (1.3 kgf-m, 9.5
lb-ft)
Clutch Operating Cylinder Assembly Removal
and Installation
S6RW0D5306008
CAUTION!
• Do not allow fluid to get on painted
surfaces. It may cause painted surface
damage.
• Do not disassemble clutch operating
cylinder assembly.

Removal
1) Clean around reservoir cap of brake master cylinder
and take out fluid with syringe or such.
2) Dismount transaxle assembly referring to “Manual
Transaxle Unit Dismounting and Remounting in
Section 5B”.
3) Loosen clutch fluid pipe flare nut (1) of clutch
operating cylinder assembly (2).
4) Remove clutch pipe joint sleeve (3) from transaxle
and then remove clutch fluid pipe (4).
5) Remove clutch operating cylinder assembly from
transaxle.
3. Brake booster
1
3
2
4
I5RW0A530006-01
“A”
I5RW0A530007-01
3
4
2
1
I5RW0A530008-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-6
Installation
1) Install clutch operating cylinder assembly (2) to
transaxle. Tighten new 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 transaxle
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 transaxle assembly referring to “Manual
Transaxle Unit Dismounting and Remounting in
Section 5B”.
5) Bleed air from system and check clutch pedal free
travel. Refer to “Air Bleeding of Clutch System” and
“Clutch Pedal Inspection”.
Clutch Operating Cylinder Assembly InspectionS6RW0D5306013
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 ComponentsS6RW0D5306010
3
4
(a)
2
1, (b)
I5RW0A530009-01
I5RW0B530005-03
2
1
3(a)
6
4
5
(b)
I6RW0C530001-01
1. Clutch cover 4. Flywheel : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
2. Clutch disc 5. Input shaft bearing : 70 N⋅m (7.0 kgf-m, 51.0 lb-ft)
3. Clutch cover bolt 6. Flywheel bolt : Do not reuse.

Downloaded from www.Manualslib.com manuals search engine 5C-7 Clutch:
Clutch Cover, Clutch Disc and Flywheel
Removal and Installation
S6RW0D5306011
Removal
1) Dismount manual transaxle assembly referring to
“Manual Transaxle Unit Dismounting and
Remounting in Section 5B”.
2) Hold flywheel 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) from flywheel (2), use
the following special tool if necessary.
Special tool
(A): 09921–26020
(B): 09930–301044) Remove flywheel (1) from crankshaft using special
tool.
Special tool
(A): 09924–17810
Installation
NOTE
Before assembling, make sure that flywheel
surface and pressure plate surface have
been cleaned and dried thoroughly.

1) Install flywheel (2) to crankshaft and tighten new
bolts (1) to specification.
Special tool
(A): 09924–17810
Tightening torque
Flywheel bolt (a): 70 N·m (7.0 kgf-m, 51.0 lb-ft)
I4RS0A530014-01
I2RH01530023-01
I4RS0A530015-02
I2RH01530024-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-8
2) Using special tool, install input shaft bearing to
flywheel (1).
Special tool
(B): 09925–98210
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 little by little to match
the splines.

Clutch Cover, Clutch Disc and Flywheel
Inspection
S6RW0D5306012
Input Shaft Bearing
Check bearing (1) for smooth rotation and replace it if
abnormality is found.
I4RS0A530016-01
I4RS0A530017-01
1
“A”I5RW0A530013-01
I3RM0A530014-01

Downloaded from www.Manualslib.com manuals search engine 5C-9 Clutch:
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 rivet holes (2), replace 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.)Clutch Cover
1) 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.
Specifications
Tightening Torque SpecificationsS6RW0D5307001
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 “Fasteners Information in Section 0A”.
I4RS0A530019-01
I3RM0A530015-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Clutch master cylinder nut 13 1.3 9.5)
Clutch operating cylinder assembly mounting
bolt10 1.0 7.5)
Clutch fluid pipe flare nut 16 1.6 11.5)
Flywheel bolt 70 7.0 51.0)
Clutch cover bolt 23 2.3 17.0)

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Special Tools and Equipment
Recommended Service MaterialS6RW0D5308001
Special ToolS6RW0D5308002
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)
))
09924–17810 09924–17811
Flywheel holder (drive plate
stopper)Flywheel holder
) / )) / )
09925–98210 09930–30104
Input shaft bearing installer Sliding shaft
))

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