2003 Suzuki XL-7 Base, 4WDFACTORY OEM SERVICE PROCEDURE

Throttle Position Sensor

NOTE: Perform all voltage and resistance tests using a Digital Volt-Ohm Meter (DVOM) with a minimum 10-megohm input impedance.
THROTTLE POSITION SENSOR RESISTANCE

Application (1) Ohms
Aerio
Between Terminals No. 1 & 2 100-6500
Between Terminals No. 1 & 3 (2) 4000-6000
Grand Vitara & XL-7
Between Terminals No. 1 & 3 4000-6000
Between Terminals No. 2 & 3 (2) 0-4600
Vitara
Between Terminals No. 1 & 2 (2) 20-6000
Between Terminals No. 1 & 3 4000-6000
XL-7
Between Terminals No. 1 & 2 (2) 20-6000
Between Terminals No. 1 & 3 4000-6000
(1) See Fig 1 for terminal identification.
(2) Varying depending on degree of throttle valve opening.
Fig 1: Identifying Throttle Position Sensor Terminals (Typical)
G98C10654Courtesy of SUZUKI OF AMERICA CORP.
THROTTLE POSITION SENSOR VOLTAGE

Application (1) Volts
Aerio (2)(3)
Throttle Fully Close .35-.65
Throttle Fully Open 3.5-4.5
Grand Vitara (2)(3)
Throttle Fully Close .35-.65
Throttle Fully Open 3.5-4.5
Vitara (2)(3)
Throttle Fully Close .50-1.2
Throttle Fully Open 3.4-4.7
XL-7 (2)(3)
Throttle Fully Close .49-.91
Throttle Fully Open 3.76-4.36
(1) Ignition ON engine off.
(2) Measure TP sensor voltage using Suzuki scan tool connected to DLC and ignition switch in LOCK position. See Figure.
(3) With engine at normal operating temperature.
Factory Service Tools

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When to See a Mechanic

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

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