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Throttle Body: Installation

  1. Clean mating surfaces and install throttle body gasket to intake manifold. Use a new gasket. See Fig 2 .
  2. Install throttle body to intake manifold and tighten bolts and nuts.
  3. Coolant hoses (3) and breather hose (4). See Fig 3 .
  4. Connect couplers of TP sensor (2) and MAF sensor (1).
  5. Install air cleaner outlet hose (2) and clamp securely. See Figure .
  6. Install engine cover. See ENGINE COVER  .
  7. Connect accelerator cable. See Fig 4 . Adjust each cable play to specification. See ACCELERATOR CABLE  under ADJUSTMENTS.
  8. Refill cooling system.
  9. Connect negative cable at battery.
Fig 1: Identifying Throttle Body Components (Aerio)
G00221001Courtesy of SUZUKI OF AMERICA CORP.
Fig 2: Installing Throttle Body Gasket (Aerio)
G00221003Courtesy of SUZUKI OF AMERICA CORP.
Fig 3: Identifying Coolant & Breather Hoses (Aerio)
G00221002Courtesy of SUZUKI OF AMERICA CORP.
Fig 4: Locating Accelerator Cable & Bracket (Aerio)
G00221004Courtesy of SUZUKI OF AMERICA CORP.


  1. Clean mating surfaces and install new throttle body gasket (2) to intake collector (1). See Fig 6 .
  2. Install throttle body to intake collector and tighten bolts and nuts.
  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 water hoses to throttle body.
  15. Connect accelerator cable and A/T throttle cable (for A/T model).
  16. Install strut tower bar (1) and tighten strut tower bar mounting bolts (2) to specification. See Figure & TORQUE SPECIFICATIONS  .
  17. Install fuse/relay box.
  18. Refill cooling system.
  19. Connect negative (-) cable at battery.
  20. Adjust accelerator cable and A/T throttle cable (for A/T model) referring to ACCELERATOR CABLE  and THROTTLE CABLE  .
Fig 1: Identifying Accelerator Cable & A/T Throttle Cable (Grand Vitara & XL-7)
G00276064Courtesy of SUZUKI OF AMERICA CORP.
Fig 2: Identifying Intake Air Pipe & Surge Tank Pipe (Grand Vitara & XL-7)
G00276065Courtesy of SUZUKI OF AMERICA CORP.
Fig 3: Identifying Intake Manifold Valves & Sensors (Grand Vitara & XL-7)
G00276066Courtesy of SUZUKI OF AMERICA CORP.
Fig 4: Identifying Intake Manifold Valves & Hoses (Grand Vitara & XL-7)
G00276067Courtesy of SUZUKI OF AMERICA CORP.
Fig 5: Identifying Intake Manifold Components (Grand Vitara & XL-7)
G00276068Courtesy of SUZUKI OF AMERICA CORP.
Fig 6: Installing New Throttle Body Gasket (Grand Vitara & XL-7)
G00276069Courtesy of SUZUKI OF AMERICA CORP.


  1. Clean mating surfaces and install throttle body gasket to intake manifold. Use new gasket (1). See Fig 3 .
  2. Install throttle body to intake manifold and tighten bolts and nuts to specified torque.
  3. Connect coolant hoses (3) to throttle body. See Fig 2 .
  4. Connect couplers to TP sensor (1) and IAC valve (2) securely. See Fig 2 .
  5. Install air cleaner outlet hose.
  6. Connect accelerator cable (1) and A/T throttle cable (2), and adjust each cable play to specification. See ACCELERATOR CABLE  and THROTTLE CABLE  under ADJUSTMENTS. See Fig 1 .
  7. Refill cooling system.
  8. Connect negative cable at battery.
Fig 1: Identifying Accelerator & Throttle Cable (Vitara)
G00174094Courtesy of SUZUKI OF AMERICA CORP.
Fig 2: Identifying TP Sensor, IAC Valve & Coolant Hoses (Vitara)
G00174095Courtesy of SUZUKI OF AMERICA CORP.
Fig 3: Identifying Throttle Body Gasket
G00174096Courtesy of SUZUKI OF AMERICA CORP.


    NOTE:

    TP sensor (5), 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. See Figure . Don't put drills or wires into passages for cleaning. It causes damages in passages.

  1. Clean mating surfaces and install new throttle body gasket (2) to intake collector (1). See Figure .
  2. Install throttle body to intake collector and tighten bolts and nuts.
  3. Connect 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 breather hose, EVAP canister purge valve hose and PCV 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 wire connector.
  10. Connect connectors of TP sensor and IAC valve.
  11. Install surge tank pipe to intake manifold with new gaskets and intake air pipe to throttle body. Install surge tank cover.
  12. Connect water hoses to throttle body.
  13. Connect accelerator cable and A/T throttle cable (for A/T model).
  14. Install strut tower bar (1) and tighten strut tower bar mounting bolts (2) to specification. See Figure & TORQUE SPECIFICATIONS  .
  15. Install fuse/relay box.
  16. Refill cooling system.
  17. Connect negative (-) cable at battery.
  18. Adjust accelerator cable and A/T throttle cable (for A/T model) referring to ACCELERATOR CABLE  and THROTTLE CABLE  .
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