Clutch Cover, Clutch Disc and Flywheel Removal and Installation: Installation

WARNING: This page is about a different car, the 2004 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Before installation, make sure that flywheel surface and pressure plate surface have been cleaned and dried thoroughly.

Install flywheel (1) to crankshaft and tighten bolts (2) to specification.
Special tool

(A): 09924-17810

"A": Sealant 99000-31110

Tightening torque

Flywheel bolt (a): 70 N.m (7.0 kg-m, 50.5 lb-ft)

Fig 1: Installing Flywheel To Crankshaft And Tightening Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool (B), install input shaft bearing to flywheel.
Special tool

(A): 09925-98210

Fig 2: Installing Input Shaft Bearing To Flywheel
Courtesy of SUZUKI OF AMERICA CORP.
Aligning clutch disc to flywheel center by using special tool (C), 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 (C) by hand so that disc centered.
- Tighten cover bolts little by little evenly in diagonal order.
Special tool

(A): 09924-17810

(B): 09923-36320

Fig 3: Installing Clutch Cover And Bolts
Courtesy of SUZUKI OF AMERICA CORP.

Tightening torque

Clutch cover bolt (b): 23 N-m (2.3 kg-m, 17.0 lb-ft)
Install clip (2) to release fork (1) and apply grease.
"A": Grease 99000-25010
Install release fork (1) and release bearing as shown in the figure.
Slightly apply grease to input shaft (3) and install clutch disc.
"B": Grease 99000-25210
Join transmission transfer assembly with engine. Refer to MANUAL TRANSMISSION ASSEMBLY DISMOUNTING AND REMOUNTING .
NOTE: Turn crankshaft with wrench from front while inserting transmission input shaft (3) to clutch disc until splines mesh.

Fig 4: Identifying Clutch Assembly Components
Courtesy of SUZUKI OF AMERICA CORP.