Suzuki Esteem, Swift 1994-02

Throttle Body

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Removal & Installation



1.3L Engine


Click image to see an enlarged view

Fig. Throttle body and intake manifold


NOTE
Do not remove the fuel pressure regulator or air valve from the throttle body. They are calibrated at the factory and are not serviceable.

  1. Relieve the fuel system pressure and disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Drain the cooling system.
  6.  
  7. Label and disconnect the throttle position sensor, fuel injector and coolant temperature electrical connectors.
  8.  
  9. Label and disconnect the fuel feed and return hoses, coolant hoses and all vacuum hoses.
  10.  
  11. Remove the accelerator cable.
  12.  
  13. Remove the throttle body attaching bolts.
  14.  
  15. Lift the throttle body from the intake manifold.
  16.  

To install:

  1. Install the throttle body on the intake manifold using a new gasket.
  2.  
  3. Tighten throttle body bolts evenly to 17 ft. lbs. (23 Nm).
  4.  
  5. Install the accelerator cable.
  6.  
  7. Connect the fuel feed and return hoses, coolant hoses and all vacuum hoses.
  8.  
  9. Connect the throttle position sensor, fuel injector and coolant temperature electrical connectors.
  10.  
  11. Refill the cooling system.
  12.  
  13. Install the air cleaner assembly.
  14.  
  15. Connect the negative battery cable. Start the engine and check for leaks.
  16.  

1.6L And 1998-2001 1.3L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Drain cooling system when engine is cold.
  4.  
  5. Remove inlet air hose.
  6.  
  7. Remove throttle position sensor coupler.
  8.  
  9. Remove accelerator cable.
  10.  
  11. Remove water hoses from throttle body.
  12.  
  13. Label and remove vacuum hoses.
  14.  
  15. Remove throttle body.
  16.  

To install:

  1. Install throttle body using a new gasket.
  2.  
  3. Connect vacuum hoses.
  4.  
  5. Connect water hoses.
  6.  
  7. Connect accelerator cable and adjust free-play to 0.32-0.35 in. (8-9mm).
  8.  
  9. Install throttle position sensor coupler.
  10.  
  11. Install inlet air hose.
  12.  
  13. Refill the engine with coolant.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Start engine and check for leaks.
  18.  

1.8L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the coolant from the vehicle.
    WARNING
    To help avoid the danger of being burned, do not remove the drain plug and the radiator cap while the engine is still hot. Scalding fluid and steam can be blown out under pressure if the plug and cap are taken off too soon.

  6.  
  7. Disconnect IAT sensor (2) wire at connector.
  8.  
  9. Remove air cleaner outlet hose (1).
  10.  
  11. Disconnect accelerator cable (1) from throttle body.
  12.  
  13. Disconnect the following electric lead wires:

    MAF sensor connector
     
    TP sensor connector
     
    Ground terminal from throttle body
     

  14.  
  15. Disconnect the following hoses:

    Coolant hoses from throttle body and cylinder head
     
    Breather hose from throttle body
     

  16.  
  17. Remove throttle body (1) from intake manifold (3).

    Click image to see an enlarged view

    Fig. Throttle body (1), throttle body gasket (2) and intake manifold (3)-1.8L engine

  18.  

To install:

  1. Clean mating surfaces and install a new throttle body gasket to intake manifold..
  2.  
  3. Install throttle body to intake manifold and tighten bolts and nuts.
  4.  
  5. Connect the following hoses:

    Coolant hoses to throttle body and cylinder head
     
    Breather hose to throttle body
     

  6.  
  7. Connect the following electric lead wires:

    MAF sensor
     
    TP sensor
     
    Ground terminal to throttle body
     

  8.  
  9. Connect accelerator cable to throttle body.
  10.  
  11. Adjust accelerator cable play as follows:


    1. Warm up engine to normal operating temperature. And check to make sure that fast idle control cam is off cam follower lever.
    2.  
    3. With throttle valve closed, check accelerator pedal play which should measure 0.08-0.27 inch (2-7mm). If measured value is out of specification, adjust it to specification with cable adjusting nut.
    4.  
    5. With accelerator pedal depressed fully, check clearance between throttle lever and lever stopper (throttle body) which should measure 0.02-0.07 inch (0.5-2.0mm). If measured value is out of specification, adjust it to specification by changing height of pedal stopper bolt.
    6.  

  12.  
  13. Install air cleaner outlet hose.
  14.  
  15. Connect IAT sensor wire at connector.
  16.  
  17. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
  18.  
  19. Refill cooling system.
  20.  
  21. Connect negative cable at battery.
  22.  
  23. Finally, start engine and check for engine coolant leaks.
  24.  

 
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