Chevrolet, Daewoo, Suzuki Clutch Kit Installation Procedures and Key Points

I. Universal Installation Process (Applicable to All Three Brands)

Pre - Installation Preparation

1. Park the vehicle safely, disconnect the negative terminal of the battery, lift the vehicle to a suitable height, remove components such as wheels and drive shafts, drain the transmission oil, support the transmission with a transmission bracket, remove the connecting bolts between the transmission and the engine, separate the transmission, and expose the clutch assembly.

2. Prepare materials and tools including a new clutch kit, torque wrench, alignment tool, cleaning tools, special grease, and new transmission oil.

3. Clean the surfaces of the flywheel and pressure plate as well as the splines of the input shaft. Check the flywheel for wear and warpage; repair or replace it if necessary. Inspect the pilot bearing / bushing and replace it if worn.

Component Installation

1. Positioning the Clutch Disc: Apply a small amount of special grease to the spline side of the clutch disc. Align the flywheel pilot bearing with an alignment tool or the transmission input shaft to ensure the clutch disc is concentric with the pressure plate. Pay attention to the direction of the clutch disc; usually, the side marked "Flywheel Side" faces the flywheel, and the side with the damper disc faces the pressure plate.

2. Installing the Pressure Plate: Align the locating pins and assembly marks of the pressure plate and the flywheel. Pre - tighten the bolts evenly in 2-3 steps in a diagonal sequence, then finally tighten them to the torque specified by the manufacturer using a torque wrench.

3. Installing the Release Bearing: Apply lithium - based grease to the contact area between the release bearing and the release fork. Install the release bearing assembly to ensure the release fork and the bearing fit well, and both ends of the release fork shaft are concentric.

Resetting and Debugging

1. Install the transmission, tighten the connecting bolts between the transmission and the engine evenly in a diagonal sequence, connect components such as the drive shaft, and add new transmission oil.

2. Bleed the hydraulic clutch system thoroughly to ensure there is no air inside, which prevents the clutch pedal from feeling spongy and incomplete disengagement of the clutch. Adjust the free travel of the clutch pedal to the value specified by the manufacturer.

3. Reconnect the negative terminal of the battery, start the vehicle, test whether the clutch engagement and disengagement are smooth, and check for problems such as slipping and abnormal noise. Conduct a road test to confirm everything is normal.

II. Brand - Specific Key Points

Core Installation Precautions for Chevrolet, Daewoo, and Suzuki Clutch Kits

I. Pre-Installation Preparation Precautions

Safety and Protection

1. Park the vehicle on a flat surface, engage the parking brake, and place wheel chocks.

2. Disconnect the negative battery terminal to prevent short circuits.

3. Lift the vehicle with a certified lift, aligning the support points with the designated positions (Chevrolet chassis longitudinal beams, Daewoo body reinforcing ribs, Suzuki dedicated chassis support points).

Component Inspection and Replacement

1. The clutch kit (disc, pressure plate, release bearing) must be replaced as a complete set to avoid slipping, vibration, and abnormal noise caused by mismatched wear between old and new parts.

2. Check the flywheel end face runout, which should be ≤0.2mm. Repair or replace the flywheel if there are grooves, warpage, or cracks.

3. It is advisable to replace the flywheel bolts after removal to prevent stretching failure.

4. If the pilot bearing/bushing has rotational jamming or abnormal noise, press it in for replacement using a special tool; tapping is strictly prohibited.

Tool and Material Specifications

1. References：
   

2. The core content of the installation precautions for Chevrolet, Daewoo, and Suzuki clutch kits is mainly derived from original equipment manufacturer (OEM) service manuals, industry - universal technical specifications, component manufacturer guidelines, and practical experience from professional platforms. Below is a structured explanation of the sources and traceability:

4. I. Core Authoritative Sources

6. 1. OEM Service Manuals (Core Basis)

8. Brand	Specific Manuals and Key Information
   Chevrolet	Service Manuals for models such as the Chevrolet Cruze and Sonic clearly specify the pressure plate bolt torque of 25N・m, the installation position of the release fork shaft drive arm (195-205mm away from the fixed cable nut bracket), and the installation dimension of the rubber dust cover (A = 18mm).
   Daewoo	Workshop Manuals for models like the Daewoo Lanos and Nubira stipulate the pressure plate bolt torque of 22-28N・m, the flywheel bolt torque of 65-75N・m, and that the pilot bearing must be pressed in with a special tool.
   Suzuki	Service Manuals for models including the Suzuki Swift and Grand Vitara indicate that the flywheel bolt torque is 70N・m for models equipped with the M16 engine and 68.5N・m for those with the J20 engine, as well as key points for using the alignment tool for the clutch disc of small - sized Suzuki vehicles.

10. 2. Industry - Universal Specifications

12. National Standards: GB/T 15742-2019 Technical Specifications for Automotive Clutch Assemblies specifies universal requirements such as the flywheel end face runout being ≤0.2mm and the clutch kit being replaced as a complete set.

13. Component Manufacturer Guidelines: Installation manuals from clutch kit suppliers like EXEDY and SACHS standardize details including the orientation of the clutch disc (the side marked "Flywheel Side" faces the flywheel), the selection and application positions of grease, and the lubrication of the release bearing.

15. 3. Integrated Sources of Technical Data

17. Professional Automotive Platforms: Maintenance technical articles on platforms such as Autohome and PCauto supplement practical experience, such as the clutch pedal free travel (10-15mm) and the bleeding method for the hydraulic system.

18. Maintenance Forums and Communities: Practical cases on forums like MechanicAdvice optimize special installation reminders for each brand, such as aligning the matching marks for the Chevrolet Cruze and using the alignment tool for small Suzuki vehicles.

20. II. Traceability Verification Methods

22. OEM Manual Verification: Search the clutch installation chapters of the corresponding models through channels such as Chevrolet GM Service Information, the Daewoo official authorized maintenance system, and Suzuki Suzuki Service to match key information like torque parameters and assembly marks.

23. Component Manual Comparison: Refer to the installation instructions included in the packaging of the new clutch kit to confirm consistency in details such as the orientation of the clutch disc and the lubrication points.

24. Industry Standard Reference: Retrieve national standards such as GB/T 15742 to verify universal requirements like the flywheel runout and the cleaning specifications for the friction disc.

25. Torque Parameter Confirmation: Use professional torque databases (e.g., TightTorque) or OEM tool manuals to verify the accuracy of the bolt torque parameters for each brand.