LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Suzuki >> 2002 >> XL-7 Plus >> Repair and Diagnosis >> External Pages >> Different car >> Section 153 (Engine Mechanical) >> Repair Instructions >> Throttle Body Removal and Installation >> Installation
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Throttle Body Removal and Installation: Installation

WARNING: This page is about a different car, the 2004 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean mating surfaces and install throttle body gasket to intake collector (1) with new gasket (2).
    Fig 1: Installing Throttle Body Gasket To Intake Collector With New Gasket
    G02256676Courtesy of SUZUKI OF AMERICA CORP.
  2. Install throttle body to intake collector and tighten bolts.
  3. Connect IAC valve hose and PCV hose.
  4. Install throttle body and intake collector to intake manifold with new intake collector gaskets.
  5. Install EGR pipe with new gaskets.
  6. Connect PCV hose, breather hose and EVAP canister purge valve hose.
  7. Connect connectors of EVAP canister purge valve and EGR valve. Fix wire harness with clamps.
  8. Install clamp bracket to intake collector.
  9. Connect ground terminal to intake manifold.
  10. Connect connectors of TP sensor, MAF sensor and IAC valve.
  11. Connect connector of injector wire.
  12. Install surge tank pipe to intake manifold with new gaskets and intake air pipe to throttle body.
  13. Install surge tank cover.
  14. Connect engine coolant hoses to throttle body.
  15. Connect accelerator cable and A/T throttle cable (A/T).
  16. Install strut tower bar (1) and tighten bolts.
    Fig 2: Installing Strut Tower Bar & Tightening Bolts
    G02256677Courtesy of SUZUKI OF AMERICA CORP.
  17. Refill cooling system referring to "COOLING SYSTEM FLUSH AND REFILL ".
  18. Connect negative cable at battery.
  19. Adjust accelerator cable and A/T throttle cable referring to "Accelerator Cable Adjustment  and A/T Throttle Cable Adjustment (for A/T Vehicle)  ".