Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSSUZUKI1990SAMURAIREPAIR AND DIAGNOSISENGINE PERFORMANCEENGINE CONTROLS - ADJUSTMENTSTHROTTLE POSITION SENSOR (TPS)TPS ADJUSTMENT
1990 Suzuki Samurai
TPS Adjustment
1990 Suzuki SamuraiSECTION TPS Adjustment
- Disconnect TPS harness connector and throttle opener vacuum hose. Using hand vacuum pump, apply 15 in. Hg vacuum to throttle opener to move throttle lever to idle position. Insert .012" (.30 mm) shim thickness gauge between throttle lever and throttle stop screw. See Figure .
- Connect ohmmeter between terminals "C" (Black/Green wire) and "D" (Blue wire) of TPS connector. Loosen TPS mounting bolts and turn TPS fully clockwise, then turn TPS counterclockwise slowly to find position ohmmeter changes from infinity to 0 (zero) ohm. Tighten TPS mounting bolts at that position.
- Ensure there is NO continuity between terminals "C" and "D" when 0.016" (0.4 mm) shim thickness gauge is inserted between throttle lever and throttle stop screw.
- Ensure there is continuity between terminals "C" and "D" when 0.008" (0.2 mm) shim thickness gauge is inserted between throttle lever and throttle stop screw.
- If steps 3) and 4) DO NOT result as indicated, TPS zero adjustment is incorrect, start adjustment sequence again. If second adjustment results are the same after readjusting, replace TPS.
- After final adjustment is completed, reconnect TPS connector and vacuum hose to throttle opener.
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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.