Suzuki: Idle surge, chilton manuals, hand torch


Question
This car is a 94 Samurai with 106 K miles. In an effort to overcome this issue we have installed new plugs, Oxygen sensor, oil and filter change. Repaired all exhaust system leaks.

At this point I am stumped. The car runs fine when above idle. At idle it will surge to the point of stall. It also acts like it floods when turned off. I.e.; stubborn to start unless the throttle is depressed, then it fires right up. I used a propane hand torch to see if any vacuum leak could be discovered. None were found. From what I read here it sounds like this may be a rare issue. I could not find reference to a similar difficulty. Your assistance would be greatly appreciated.


Answer
It's probable that the idle position sensor is either out of adjustment or defective, and the ECM isn't getting the correct signals.

Unfortunately, my vehicle is an 87 with carburetor, and it's shop manual doesn't cover that.  Look online, and you can probably find a download of a factory service manual.  The motors, haines and chilton manuals do not have the adjustment procedure, so don't waste your money on one of them.  You will have to get a factory manual to get the correct procedure, and faking it will almost never work. I know, I'm a 30+yr professional, and tried on a friend's, and couldn't get it to work right until he got a factory manual, and I used the factory procedure.....Sorry it's been about ten years, and I don't remember it......