Front Upper Valve Body Components: Disassembly

WARNING: This page is about a different car, the 2004 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Remove throttle valve keep plate (1).

Fig 1: Removing Throttle Valve Keep Plate
Courtesy of SUZUKI OF AMERICA CORP.
Using screwdriver with vinyl tape or the like wound around its tip, hold cut back valve plug and remove cut back retainer (1) with magnet. Then remove cut back plug, cut back valve and cut back valve spring.

Fig 2: Removing Cut Back Plug, Valve & Spring
Courtesy of SUZUKI OF AMERICA CORP.
Remove one cover bolt on front valve and cover (1) and loosen the other to move cover as shown in figure. Remove secondary regulator valve sub assembly and secondary regulator valve spring. Then remove remaining loose cover bolt to remove front valve end cover.
WARNING: When moving cover, be sure to hold valve with finger to prevent secondary regulator valve sub assembly from jumping out.

Fig 3: Remove Cover Bolt On Front Valve
Courtesy of SUZUKI OF AMERICA CORP.
Remove throttle cam bolt (1) and then remove throttle valve cam (2), throttle cam return spring (4) and cam spacer (3).

Fig 4: Removing Throttle Cam Bolt
Courtesy of SUZUKI OF AMERICA CORP.
With throttle valve held as shown in the figure, remove locating pin (1) with magnet (2) and then remove throttle valve and throttle valve primary spring.

Fig 5: Removing Locating Pin With Magnet
Courtesy of SUZUKI OF AMERICA CORP.
Remove throttle valve and then remove throttle valve secondary spring and throttle valve compensating ring(s) (1).
NOTE: Write down how many throttle valve compensating rings there were, for throttle pressure varies with number of them.

Fig 6: Removing Throttle Valve

Courtesy of SUZUKI OF AMERICA CORP.