Clutch Cover and Clutch Disc Removal and Installation: Installation

Reference: CLUTCH COVER AND CLUTCH DISC INSPECTION 

1. Hold flywheel with special tool (A).
2. Install clutch disc and clutch cover (1) to flywheel temporarily.
3. Align center of clutch disc and center of flywheel using special tool (B).
4. Install and tighten clutch cover bolts using the following procedures:
   1. Tighten 3 bolts (3) by hand.
   2. Tighten other 3 bolts (4) evenly and gradually to 5.0 N.m (0.51 kgf-m, 4.0 lbf-ft).
   3. Fully tighten all bolts (3), (4) evenly and gradually to specified torque in numerical order ("1" - "6") starting from bolt nearby strut plate rivet (2).
      NOTE: Tighten the clutch cover bolts while checking that the special tool can slide smoothly.

      Special Tool 

      1. 09924-17811 
      2. 09923-37910 

      Tightening torque 

      Clutch cover bolt* (a): 5.0 N.m → 23 N.m (0.51 kgf-m → 2.3 kgf-m, 4.0 lbf-ft → 17.0 lbf-ft) 

      Clutch cover bolt* (b): 23 N.m (2.3 kgf-m, 17.0 lbf-ft) 

      Fig 1: Identifying Clutch Cover Bolts

      Courtesy of SUZUKI OF AMERICA CORP.
5. Slightly apply grease to input shaft (1), and then join manual transaxle assembly with engine, see MANUAL TRANSAXLE UNIT DISMOUNTING AND REMOUNTING .

   "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 spline.
   Fig 2: Identifying Input Shaft

   Courtesy of SUZUKI OF AMERICA CORP.