2003 Suzuki Aerio L4-2.0LFACTORY OEM SERVICE PROCEDURE

Throttle Position Sensor: Adjustments






Throttle Position (TP) Sensor Adjustment

Throttle Position (TP) Sensor On-Vehicle Inspection
1) Warm up engine to normal operating temperature.
2) Check to make sure that fast idle cam and cam follower lever are not in contact with each other. If they are, check fast idle control system.
3) Loosen TP sensor screws.
4) When SUZUKI scan tool and cartridge are available, set them to DLC with ignition switch OFF.

When they are not available, remove ECM referring to Service and Repair Engine Control Module (ECM) Removal and Installation
and with couplers connected to ECM, connect digital type voltmeter as shown in figure [B].
Special Tool
SUZUKI scan tool (Tech 2 kit)

Factory service manual diagram




Factory service manual diagram




5) Turn TP sensor (1) clockwise or counterclockwise and tighten TP sensor screw at a position where voltage as specified is obtained.

TP sensor voltage when throttle is fully close
0.50 ± 0.15 V

Tightening torque
TP sensor screw (a): 2.5 Nm (0.25 kgf-m, 1.8 lbf-ft)

6) Check to make sure that TP sensor voltage is specified value when throttle is fully open.

TP sensor voltage when throttle is fully open
4.0 ± 0.5 V

7) Install ECM if removed.
8) With ignition switch OFF, disconnect battery negative cable from battery for 5 minutes or more.

9) Connect negative cable to battery.

Factory service manual diagram




Factory Service Tools

Use the Manual With the Right Hardware

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • β€’ You smell fuel, burning insulation, or see smoke.
  • β€’ Brakes feel soft, pull hard to one side, or make grinding noises.
  • β€’ The engine overheats, stalls repeatedly, or misfires under load.
  • β€’ You are missing required tools, torque specs, or safe lifting equipment.
  • β€’ You are not confident in the next step or safety outcome.