Alero, Grand Am 1999-2005

Throttle Body

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Removal & Installation



2.2L Engine

WARNING
Do not use solvent of any type when cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as damage to the gasket surfaces and throttle body assembly may result. Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces.


WARNING
Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components.

  1. Remove the air cleaner resonator.
  2.  
  3. Disconnect the Idle Air Control (IAC) valve harness connector.
  4.  
  5. Disconnect the Throttle Position (TP) sensor harness connector.
  6.  
  7. Disconnect the vacuum hoses at the throttle body.
  8.  
  9. Remove the accelerator control bracket and cables from the throttle body.
  10.  
  11. Remove the throttle body attaching bolts and studs (1).
  12.  
  13. Remove the throttle body (4) from the intake manifold.

    Click image to see an enlarged view

    Fig. Exploded view of the throttle body (4) and related components-2.2L engine

  14.  

To install:

  1. Inspect the throttle body gasket (3) and replace if necessary.
  2.  
  3. Install the throttle body (4) to the intake manifold.
  4.  
  5. Install the throttle body attaching bolts and studs (5). Tighten the throttle body attaching bolts and studs to 89 inch lbs. (10 Nm).
  6.  
  7. Install the accelerator cable bracket and cables.
  8.  
  9. Connect the vacuum hoses to the throttle body.
  10.  
  11. Connect the TP sensor harness connector .
  12.  
  13. Connect the IAC valve harness connector .
  14.  
  15. Install the air cleaner resonator.
  16.  
  17. Test the accelerator movement by depressing the pedal to the floor and releasing the pedal.
  18.  

2.4L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner resonator from the throttle body.
  4.  
  5. Disconnect the wiring from the IAC valve and TP sensor.
  6.  
  7. Label and disconnect all vacuum hoses attached to the throttle body.
  8.  
  9. Label and remove the throttle, cruise and transmission control cables.
  10.  
  11. Unbolt and remove the accelerator cable bracket.
  12.  
  13. Remove the MAP sensor.
  14.  
  15. Unbolt the throttle body and lift the unit from the manifold.
  16.  
  17. Remove all traces of gasket from the throttle body and manifold mating surfaces.
    NOTE
    The EVAP canister may have released carbon particles which may have caused this parts failure. Check the EVAP canister for carbon before returning to the vehicle to service.



    Click image to see an enlarged view

    Fig. Remove the throttle body bolts and lift the unit from the manifold-2.4L engine

  18.  

To install:

  1. Place a new gasket into position and set the throttle body on top. Do not install the set bolts at this time.
  2.  
  3. Attach the accelerator cable bracket.
  4.  
  5. Install the MAP sensor.
  6.  
  7. Install the throttle body bolts and tighten to 58 inch lbs. (6 Nm).
  8.  
  9. Attach the throttle, cruise and transmission control cables to the throttle body.
  10.  
  11. Install all vacuum hoses to the throttle body.
  12.  
  13. Attach the electrical wiring to the IAC valve and TP sensor.
  14.  
  15. Install the air cleaner resonator to the throttle body.
    NOTE
    With the engine OFF, check to see that the accelerator pedal is free, by depressing the pedal to the floor and releasing.

  16.  
  17. Connect the negative battery cable.
  18.  
  19. Reset the IAC valve pintle position:
    1. Turn the ignition switch to the ON position with the engine OFF .
    2.  
    3. Turn the ignition OFF for ten seconds.
    4.  
    5. Start the engine and check for proper idle operation.
    6.  

  20.  

3.1L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the air inlet duct.
  6.  
  7. Detach the IAC valve and the TP sensor electrical connectors.
  8.  
  9. Disconnect the throttle and cruise control cables.
  10.  
  11. Unfasten the accelerator cable bracket bolts, then remove the bracket.
  12.  
  13. Remove the engine coolant pipe nut to gain access to the throttle body attaching stud.
  14.  
  15. Unfasten the throttle body retaining nut/stud, then remove the throttle body assembly. Remove and discard the flange gasket.
  16.  
  17. Clean the gasket mating surfaces.
    CAUTION
    Be careful when cleaning the mating surfaces because sharp tools may scratch and/or damage the sealing surfaces.



    Click image to see an enlarged view

    Fig. Removing the throttle body assembly-3.1L engine

  18.  

To install:

  1. Position a new flange gasket, then install the throttle body assembly and secure with the retaining bolt/stud. Tighten to 18-21 ft. lbs. (25-28 Nm).
  2.  
  3. Fasten the coolant pipe nut, then install the accelerator cable bracket.
  4.  
  5. Connect the throttle and cruise control cables.
    NOTE
    Make sure the throttle and cruise control linkage does not hold the throttle open.

  6.  
  7. Attach the TP sensor and IAC valve electrical connectors.
  8.  
  9. Install the air inlet duct, then connect the negative battery cable.
  10.  
  11. With the engine OFF , check to make sure the accelerator pedal if free by depressing it to the floor, then releasing it.
  12.  

3.4L Engine
  1. Drain coolant.
  2.  
  3. Disconnect the Intake Air Temperature (IAT) sensor electrical connector.
  4.  
  5. Disconnect the breather tube from the air intake tube.
  6.  
  7. Remove the air intake tube.
  8.  
  9. Disconnect the Idle Air Control (IAC) valve electrical connector.
  10.  
  11. Disconnect the Throttle Position (TP) sensor electrical connector.
  12.  
  13. Disconnect the accelerator controls cable from the throttle lever and accelerator bracket.
  14.  
  15. If applicable disconnect the cruise control cable from the throttle lever and accelerator bracket.
  16.  
  17. Remove the accelerator control cable bracket.
  18.  
  19. Disconnect the throttle body coolant bypass hoses.
  20.  
  21. Disconnect the heater pipe nut at the throttle body.
  22.  
  23. Remove the nuts and bolts holding the throttle body to the intake manifold.
  24.  
  25. Remove the throttle body assembly.
  26.  

To install:


WARNING
Do not use solvent of any type when cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as damage to the gasket surfaces and throttle body assembly may result. Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces.

  1. Clean the gasket surface on the intake manifold and the throttle body assembly.
  2.  
  3. If necessary, install a new gasket.
  4.  
  5. Install the throttle body assembly.
  6.  
  7. Install the throttle body retaining nuts and bolts. Tighten the throttle body retaining nuts and bolts to 21 ft. lbs. (28 Nm).
  8.  
  9. Connect the throttle body coolant bypass hoses.
  10.  
  11. Connect the heater pipe nut at the throttle body.
  12.  
  13. Connect the IAC valve electrical connector.
  14.  
  15. Connect the TP sensor electrical connector.
  16.  
  17. Install the accelerator controls cable bracket.
  18.  
  19. If applicable connect the cruise control cable to the throttle lever and accelerator bracket.
  20.  
  21. Connect the accelerator controls cable to the throttle lever and accelerator bracket.
  22.  
  23. Install the air intake tube. Tighten the air cleaner duct clamp to 18 inch lbs. (2 Nm).
  24.  
  25. Connect the IAT sensor electrical connector.
  26.  
  27. Connect the breather tube into the air intake tube.
  28.  
  29. Refill the coolant.
    NOTE
    The throttle should operate freely without binding between full closed and wide open throttle.

  30.  
  31. Inspect for complete throttle opening and closing positions by operating the accelerator pedal. Also inspect for poor carpet fit under the accelerator pedal.
  32.  

 
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