Aerio, Esteem & Grand Vitara

WARNING: This page is about a different car, the 2002 Suzuki XL-7, 2002 Suzuki Vitara, 2002 Suzuki Grand Vitara, 2002 Suzuki Esteem, and 2002 Suzuki Aerio. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: This model uses thermo wax to control a plunger and lever outside throttle body.

Check throttle valve lever moves freely. Measure plunger protrusion of fast idle control arm with coolant temperature at 77°F (25°C). See Fig 1 . Plunger measurement should be 1.048-1.078 in. (26.6-27.4 mm).
Start engine, check that higher than normal idle speed exists. As engine coolant temperature increases, fast idle speed should gradually reduce. As engine coolant temperatures reach 126-154°F (52-68°C), check to make sure fast control cam is off cam follower lever. See Fig 2 . If fast idle valve does not operate as specified, valve could be faulty or coolant passage could be blocked. If no problem is found with coolant passage, replace throttle body assembly.

Fig 1: Identifying Plunger Position Engine Cold (Aerio, Esteem & Grand Vitara 2.5L)

Courtesy of SUZUKI OF AMERICA CORP.

Fig 2: Identifying Fast Idle Cam Position Engine Hot (Aerio, Esteem & Grand Vitara 2.5L)

Courtesy of SUZUKI OF AMERICA CORP.