Suzuki Vitara, Grand Vitara, XL7 2000-06

Throttle Body

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Removal & Installation



1.6L & 2.0L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain cooling system.
  6.  
  7. Disconnect accelerator cable and/or A/T throttle cable from throttle body.
  8.  
  9. Remove air cleaner outlet hose.
  10.  
  11. Disconnect electric coupler from TP sensor and IAC valve.
  12.  
  13. Disconnect coolant hoses from throttle body.
  14.  
  15. Remove throttle body from intake manifold.
  16.  

To install:

  1. Clean mating surfaces and install throttle body gasket to intake manifold. Use new gasket.
  2.  
  3. Install throttle body to intake manifold and tighten bolts and nuts.
  4.  
  5. Connect coolant hoses to throttle body.
  6.  
  7. Connect couplers to TP sensor and IAC valve securely.
  8.  
  9. Install air cleaner outlet hose.
  10.  
  11. Connect accelerator cable and A/T throttle cable, and adjust each cable
  12.  
  13. Refill cooling system.
  14.  
  15. Connect negative cable at battery.
  16.  

2.5L & 2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect negative cable at battery.
  4.  
  5. Drain cooling system.
  6.  
  7. Remove strut tower bar.
  8.  
  9. Disconnect accelerator cable and/or A/T throttle cable from throttle body.
  10.  
  11. Disconnect water hose from throttle body.
  12.  
  13. Remove surge tank cover.
  14.  
  15. Remove intake air pipe and surge tank pipe.
  16.  
  17. Disconnect connector of injector wire.
  18.  
  19. Disconnect connectors of TP sensor, MAF sensor and IAC valve.
  20.  
  21. Disconnect ground terminal from intake manifold.
  22.  
  23. Remove clamp bracket from intake collector.
  24.  
  25. Disconnect connectors of EVAP canister purge valve and EGR valve.
  26.  
  27. Disconnect PCV hose, breather hose and EVAP canister purge valve hose.
  28.  
  29. Remove EGR pipe.
  30.  
  31. Remove throttle body and intake collector from intake manifold.
  32.  
  33. Disconnect hoses of IAC valve and PCV from throttle body.
  34.  
  35. Remove throttle body from intake collector.
    WARNING
    MAF sensor, TP sensor , or other components containing rubber must not be placed in a solvent or cleaner bath. A chemical reaction will cause these parts to swell, harden or get distorted. Don-t put drills or wires into passages for cleaning. It causes damages in passages.

  36.  

To install:

  1. Clean mating surfaces and install throttle body gasket to intake collector with new gasket.
  2.  
  3. Install throttle body to intake collector and tighten to 17 ft. lbs (23 Nm).
  4.  
  5. Connect IAC valve hose and PCV hose.
  6.  
  7. Install throttle body and intake collector to intake manifold with new intake collector gaskets.
  8.  
  9. Install EGR pipe with new gaskets.
  10.  
  11. Connect PCV hose, breather hose and EVAP canister purge valve hose.
  12.  
  13. Connect connectors of EVAP canister purge valve and EGR valve. Fix wire harness with clamps.
  14.  
  15. Install clamp bracket to intake collector.
  16.  
  17. Connect ground terminal to intake manifold.
  18.  
  19. Connect connectors of TP sensor, MAF sensor and IAC valve.
  20.  
  21. Connect connector of injector wire.
  22.  
  23. Install surge tank pipe to intake manifold with new gaskets and intake air pipe to throttle body.
  24.  
  25. Install surge tank cover.
  26.  
  27. Connect engine coolant hoses to throttle body.
  28.  
  29. Connect accelerator cable and A/T throttle cable (A/T).
  30.  
  31. Install strut tower bar and tighten bolts.
  32.  
  33. Refill cooling system
  34.  
  35. Connect the negative battery cable.
  36.  

2.7L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain cooling system.
  6.  
  7. Remove surge tank cover.
  8.  
  9. Remove intake air pipe, surge tank pipe and IMT valve.
  10.  
  11. Disconnect connectors from electric throttle body assembly and fuel injectors of left (No.1) bank.
  12.  
  13. Disconnect fuel rail connect pipe from left fuel rail (No.1) bank.

    Click image to see an enlarged view

    Fig. Fuel connect pipe (1) and coolant hose (2) shown

  14.  
  15. Disconnect coolant hose from electric throttle body assembly.
  16.  
  17. Remove left (No.1) bank fuel rail and fuel pressure regulator.

    Click image to see an enlarged view

    Fig. Left bank fuel rail and regulator

  18.  
  19. Remove electric throttle body assembly from intake collector.
  20.  

To install:

  1. Clean mating surfaces and use new throttle body gasket.
  2.  
  3. Install electric throttle body assembly.
  4.  
  5. Install left (No.1) bank fuel rail and fuel pressure regulator.
  6.  
  7. Tighten fuel rail mounting bolts to 18 ft. lbs. (25 Nm).
  8.  
  9. Reconnect coolant hose at throttle body.
  10.  
  11. Install fuel rail connect pipe to left fuel rail (No.1) bank.
  12.  
  13. Tighten fuel union bolts to 22 ft. lbs. (30 Nm).
  14.  
  15. Reconnect connectors to electric throttle body assembly and fuel injectors of left (No.1) bank.
  16.  
  17. Install intake air pipe, surge tank pipe and IMT valve.
  18.  
  19. Install surge tank cover.
  20.  
  21. Check to ensure that all removed parts are back in place.
  22.  
  23. Refill cooling system.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Verify that there is no fuel leakage at each connection.
  28.  

 
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