Throttle Body (TBI): Overhaul

Remove fuel injector from throttle body. See INJECTOR (TBI) under FUEL SYSTEM.
Remove throttle position sensor, throttle switch (SOHC M/T), coolant (water) and temperature sensor (SOHC) from throttle body. See Fig 3 . Remove attaching screws and separate upper and lower bodies.
DO NOT soak any electrical device or air valve in solvent or other cleaner. DO NOT put drills or wires into passages. Clean upper and lower passages with compressed air only. Reassembly components with new gaskets and "O" rings.
Assemble upper and lower bodies with new gasket. On SOHC, tighten upper-to-lower body attaching screws to 25-35 INCH lbs. (2.8-3.9 N.m).
On SOHC, install coolant (water) temperature sensor. Tighten sensor to 15-22 ft. lbs (20-30 N.m). On all models, install fuel injector. See INJECTOR (TBI) . Apply thread locking compound to injector cover mounting screws and install cover.
On all models except SOHC, tighten injector cover screws to 17 INCH lbs. (1.9 N.m). On SOHC, tighten injector cover screws to 25-35 INCH lbs. (2.8-3.9 N.m).

Fig 1: Aligning Throttle Position Sensor (SOHC A/T)
Courtesy of SUZUKI OF AMERICA CORP.
On (SOHC A/T), install throttle position sensor so adjusting holes slightly cover mounting bolt holes. See Fig 1 . Turn sensor so mounting holes align.
On SOHC M/T, install throttle switch to throttle shaft by aligning flat part of throttle switch rotor with cut part of throttle shaft. See Fig 2 . Push throttle switch in until it makes full contact with throttle body.
On all models, install sensor mounting bolts (finger tighten only). Clamp wiring harness securely to side of throttle body.

Fig 2: Aligning Throttle Switch (SOHC M/T)

Courtesy of SUZUKI OF AMERICA CORP.

Fig 3: Exploded View Of Throttle Body (SOHC)

Courtesy of SUZUKI OF AMERICA CORP.