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

WARNING: This page is about a different car, the 2004 Suzuki XL-7 and 2004 Suzuki Grand 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: Tightening Flywheel Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Using special tool (B), install input shaft bearing to flywheel.
Special tool

(B): 09925-98210

Fig 2: Installing Input Shaft Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Aligning clutch disc to flywheel center by using special tool (C), install clutch cover (1) and bolts. Then tighten bolts 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

(C): 09923-36320

Tightening torque

Clutch cover bolt (b): 23 N.m (2.3 kg-m, 17.0 lb-ft)

Fig 3: Installing Clutch Cover
Courtesy of SUZUKI OF AMERICA CORP.
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.
For H25 engine model, refer to MANUAL TRANSMISSION UNIT ASSEMBLY .

For H27 engine model, refer to MANUAL TRANSMISSION UNIT ASSEMBLY .

NOTE: Turn crankshaft with wrench from front while inserting transmission input shaft (3) to clutch disc until splines mesh.

Fig 4: Identifying Input Shaft Installation

Courtesy of SUZUKI OF AMERICA CORP.