Get Engine and Emission Control System -> Air Intake System Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

ON-VEHICLE INSPECTION

Check that throttle valve lever moves smoothly.

REMOVAL

1) Disconnect negative cable at battery.

2) Drain cooling system referring to Section 6B.

3) Disconnect accelerator cable from throttle body.

4) Remove air cleaner outlet hose (1).

ENGIINE AND EMISSION CONTROL SYSTEM 6E1-51

AIR INTAKE SYSTEM

THROTTLE BODY

1. Throttle body

2. Throttle stop screw

3. TP sensor

4. O-ring

5. IAC valve

6. MAP sensor

CAUTION:

Do not remove or adjust

throttle stop screw as it is

factory adjusted precisely

CAUTION:

Do not disassemble IAC

valve. Disassembly spoils

its original performance

: Tightening torque

: Do not reuse

5) Disconnect couplers from TP sensor, MAP sensor and IAC

valve.

6) Remove throttle body from intake manifold.

7) Disconnect engine coolant hoses and EVAP canister purge

valve hose from throttle body.

1. Engine coolant hose

2. TP sensor

3. IAC valve

4. MAP sensor

5. EVAP canister purge valve hose

6. Throttle body

DISASSEMBLY

NOTE:

While disassembling and assembling throttle body, use spe-

cial care not to deform levers on throttle valve shaft or cause

damage to any other parts.

1) Remove TP sensor, MAP sensor and IAC valve from throttle

body.

CLEANING

Clean throttle body bore and idle air passage by blowing com-

pressed air.

CAUTION:

D TP sensor, IAC valve, MAP sensor or other compo-

nents containing rubber must not be placed in a sol-

vent or cleaner bath. A chemical reaction will cause

these parts to swell, harden or get distorted.

D Do not blow compressed air through bypass air pas-

sage with IAC valve installed to throttle body. This will

cause IAC valve to malfunction.

1. Throttle body bore

2. Idle bypass passage

REASSEMBLY

1) Install IAC valve to throttle body referring to IAC valve Installa-

tion section.

2) Install TP sensor to throttle body referring to TP sensor Installa-

tion section.

3) Install MAP sensor to throttle body referring to MAP sensor

Installation section.

6E1-52 ENGIINE AND EMISSION CONTROL SYSTEM

INSTALLATION

1) Clean mating surfaces and install throttle body gasket to intake

manifold.

Use new gasket.

2) Install throttle body to intake manifold.

3) Connect engine coolant hoses and EVAP canister purge valve

hose.

4) Connect couplers to TP sensor, MAP sensor and IAC valve se-

curely.

1. Engine coolant hose

2. TP sensor

3. IAC valve

4. MAP sensor

5. EVAP canister purge valve hose

6. Throttle body

5) Install air cleaner outlet hose (1).

6) Connect accelerator cable and adjust cable play to specification.

7) Refill cooling system.

8) Connect negative cable at battery.

ENGIINE AND EMISSION CONTROL SYSTEM 6E1-53

IAC VALVE

REMOVAL

1) Remove throttle body from intake manifold referring to “Throttle

Body Removal” section.

2) Remove IAC valve from throttle body.

INSPECTION

1) Remove IAC valve (1) from throttle body.

2) Connect each connector to IAC valve, MAP sensor, TP sensor

and IAT sensor.

3) Check that rotary valve (2) of lAC valve opens and closes once

and then stops in about 60 ms as soon as ignition switch is

turned ON.

NOTE:

D This check should be performed by two people, one per-

son turns on ignition switch while the other checks valve

operation.

D As valve operation is momentary, it may be overlooked.

To prevent this, perform this operation check 3 times or

more continuously.

If rotary valve of lAC valve does not operate at all, check

wire harnesses for open and short. If wire harnesses are

in good condition, replace lAC valve and recheck.

INSTALLATION

1) Install new O-ring (2) to IAC valve (1).

2) Install IAC valve to throttle body (3).

Tighten IAC valve screws to specified torque.

Tightening Torque

(a): 3.5 N·m (0.35 kg-m, 2.5 lb-ft)

3) Install throttle body to intake manifold referring to THROTTLE

BODY INSTALLATION section.

6E1-54 ENGIINE AND EMISSION CONTROL SYSTEM

Engine and Emission Control System -> Air Intake System for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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