Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Throttle Body

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3

  1. Disonnect the negative battery cable.
  2.  
  3. Drain the engine cooling system in a large, clean catch pan. The coolant can be reused, if it is clean and less than 2 years old.
  4.  
  5. Remove the throttle cover, then detach the accelerator cable and, if equipped, the automatic transmission throttle cable from the throttle body.
  6.  
  7. Remove the air intake pipe and hose.
  8.  
  9. Detach all wiring harness connectors from the throttle body.
  10.  
  11. Disconnect all vacuum and engine cooling system hoses from the throttle body.
  12.  
  13. Loosen the throttle body retaining nuts and bolts, then slide the throttle body off of the intake manifold.
  14.  
  15. Clean the throttle body-to-intake manifold gasket surfaces thoroughly.
  16.  


WARNING
If you are going to clean the throttle body, keep the following points in mind to prevent damaging the throttle body:



The TP sensor, fast idle air valve or other components fabricated with rubber should not be placed in solvent or parts cleaner. The rubber may swell, harden or distort.
 
Do not use drills or wires to clean the passages in the throttle body. It can damage the passages.
 

To install:
  1. Install a new throttle body gasket on the intake manifold.
  2.  
  3. Install the throttle body on the intake manifold. Tighten the retaining nuts and bolts to 159-248 inch lbs. (18-28 Nm).
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Be sure to use a new gasket when installing the throttle body onto the intake manifold-using an old gasket may result in vacuum leaks at this juncture



Click image to see an enlarged view

Fig. Fig. 2: Install and tighten the throttle body-to-intake manifold retaining fasteners (2 bolts and 2 nuts) in a crisscross pattern to 203 inch lbs. (23 Nm)



Click image to see an enlarged view

Fig. Fig. 3: After installing the throttle body, reattach and adjust all accelerator and transmission cables

  1. Reattach the engine cooling and vacuum hoses to the throttle body.
  2.  
  3. Attach the wiring harness connectors to the throttle body components.
  4.  
  5. Install the air intake pipe and hose.
  6.  
  7. Connect the accelerator and automatic transmission (if equipped) throttle cables to the throttle body. Adjust cable play. Accelerator cable adjustment is covered earlier in this section; automatic transmission throttle cable adjustment is described in Section 7.
  8.  
  9. Refill the engine cooling system.
  10.  
  11. Connect the negative battery cable, then start the engine and check for coolant leaks.
  12.  

 
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