Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Throttle Body

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REMOVAL & INSTALLATION



See Figures 1 through 11


CAUTION
Do not perform this procedure when the engine is hot. If fuel comes into contact with hot engine parts, a dangerous explosive condition is created.

  1. If necessary, allow the engine to cool down completely.
  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the engine cooling system into a large, clean catch pan.
  8.  
  9. Remove the air intake case from the throttle body and air cleaner hose.
  10.  



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Fig. Fig. 1: Exploded view of the throttle body, showing all of the engine control components mounted on it



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Fig. Fig. 2: To remove the throttle body, first disconnect the fuel supply line from the throttle body ...



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Fig. Fig. 3: ... then detach the fuel return hose from the pressure regulator (arrow)



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Fig. Fig. 4: Disengage the accelerator cable (A) from the throttle lever (B) ...



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Fig. Fig. 5: ... then unfasten the accelerator cable mounting bracket (arrow) from the side of the throttle body

  1. Detach the fuel supply line from the throttle body.
  2.  
  3. Detach the fuel return line from the fuel pressure regulator.
  4.  
  5. Disconnect the accelerator cable and automatic transmission kickdown cable (if equipped) from the throttle lever. Loosen the accelerator cable mounting bracket bolts, then separate the bracket from the side of the throttle body.
  6.  
  7. Detach and label all vacuum hoses from the throttle body.
  8.  
  9. Disconnect the engine cooling system hoses from the throttle body.
  10.  
  11. Detach and label the wiring harness connectors from the fuel injector, the TPS and the ISCS or IAC valve.
  12.  



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Fig. Fig. 6: Detach and label all of the vacuum lines ...



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Fig. Fig. 7: ... and engine cooling system hoses from the throttle body



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Fig. Fig. 8: Disengage all of the wiring harness connectors from the throttle body components

  1. Remove the throttle body retaining bolts, then lift the throttle body and old gasket up and off of the intake manifold.
  2.  
  3. While the throttle body is removed from the intake manifold, install clean shop rags into the intake manifold opening to prevent accidentally dropping anything into the engine.
  4.  



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Fig. Fig. 9: Loosen all of the throttle body-to-intake manifold bolts ...



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Fig. Fig. 10: ... then lift the throttle body up and off of the intake manifold



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Fig. Fig. 11: Clean the throttle body-to-intake manifold gasket surfaces thoroughly of all old gasket material and dirt

To install:
  1. Clean the throttle body-to-intake manifold gasket surfaces thoroughly.
  2.  
  3. Install a new gasket onto the intake manifold, then set the throttle body onto the intake manifold.
  4.  
  5. Install and tighten the retaining bolts to 160-248 inch lbs. (18-28 Nm).
  6.  
  7. Reattach all wiring connectors, vacuum hoses, cooling system hoses, cables and the fuel return hose to the throttle body.
  8.  
  9. Adjust the accelerator cable play.
  10.  
  11. Install a new O-ring onto the end of the fuel supply line, then lubricate the O-ring with gasoline. Attach the fuel supply line to the throttle body, and tighten the attaching bolts to 71-106 inch lbs. (8-12 Nm).
  12.  
  13. Fill the engine cooling system with the proper type and amount of coolant. The original coolant may be reused so long as it is not more than 1 year old and it is clean (free of debris and corrosion).
  14.  
  15. Conenct the negative battery cable.
  16.  
  17. Turn the ignition switch ON without starting the engine, and inspect the fuel lines around the throttle body for leaks.
  18.  
  19. Install the air intake case.
  20.  
  21. Start the engine and check for coolant leaks.
  22.  

 
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