Front Upper Valve Body Disassembly and Assembly: Disassembly

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.

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

Fig 3: Removing One Cover Bolt On Front Valve End Cover
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 And Throttle Valve Cam
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 (1) there were, for throttle pressure varies with number of them.

Fig 6: Identifying Throttle Valve Compensating Ring
Courtesy of SUZUKI OF AMERICA CORP.