Suzuki Vitara (LY) 2016-2017 · Service Manual D16AA-6M/T Model · Repair Instructions

Clutch Cover and Clutch Disc Removal and Installation

Precautions: General safety (00)

NOTICE:
The clutch cover bolt is pre-coated with adhesive.
If the bolt is reused, it may work loose.
Replace the clutch cover bolt with a new one.
Removal
1)Dismount manual transaxle. icon 
2)Install special tool to clutch cover (1).
NOTE:
Keep special tool installed until clutch cover is reinstalled.
Special Tool
(A): 09923–87910
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3)Hold flywheel with special tool and remove four clutch cover bolts (1) – (4) shown in figure.
Special Tool
(A): 09924–17811
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4)Install special tool and tighten its push rod (1) and push in diaphragm (2) until clutch disc becomes free.
Special Tool
(A): 09920–47910
(B): 09924–17811
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NOTE:
Check that clutch disc is in free condition, inserting a small flat-bladed screwdriver (1) between clutch cover (2) and flywheel (3) and push clutch disc (4).
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5)Remove two remaining clutch cover mounting bolts.
6)Loosen push rod and remove special tool, clutch cover and clutch disc.
Installation
NOTE:
Before installation, check that flywheel surface and pressure plate surface have been cleaned and dried thoroughly.
1)Aligning clutch disc with flywheel center using special tool (B), install clutch cover (1) and tighten two bolts (2) positioning on the opposite sides by hand.
2)Install special tools (A) and (D).
NOTE:
•When reinstalling clutch cover, check that special tool (C) is installed.
•When installing new clutch cover, special tool (C) is not necessary.
Special Tool
(A): 09924–17811
(B): 09923–37910
(C): 09923–87910
(D): 09920–47910
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3)Tighten push rod (1) of special tool and diaphragm until flywheel mounting surface of clutch cover touches flywheel and tighten two clutch cover bolts (2) evenly and gradually to specified torque.
Special Tool
(A): 09920–47910
(B): 09924–17811
Tightening torque
Clutch cover bolt (a): 23 N·m (2.3 kgf-m, 17.0 lbf-ft)
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4)Loosen push rod (1) and remove special tools (B) and (D).
Special Tool
(A): 09924–17811
(B): 09923–37910
(C): 09923–87910
(D): 09920–47910
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5)Tighten four remaining clutch cover bolts (1) evenly and gradually in diagonal order to specified torque.
Special Tool
(A): 09924–17811
Tightening torque
Clutch cover bolt (a): 23 N·m (2.3 kgf-m, 17.0 lbf-ft)
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6)When reinstalling clutch cover (1), remove special tool.
Special Tool
(A): 09923–87910
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7)Slightly apply grease to input shaft (1), and then join manual transaxle with engine. icon 
“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.
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