Astro, Safari 1997-2005

Throttle Body

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Removal & Installation



  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine cover.
  4.  
  5. Remove the air cleaner outlet resonator.
  6.  
  7. Remove the air cleaner outlet resonator adapter stud.
  8.  
  9. Remove the cruise control cable.
  10.  
  11. Remove the stud and nuts retaining the accelerator control cable bracket and position bracket aside.
  12.  
  13. Disconnect the (IAC) valve harness connector.
  14.  
  15. Disconnect the (TP) sensor harness connector.
  16.  
  17. Remove the throttle body retaining studs.
  18.  
  19. Remove the throttle body assembly.
  20.  
  21. Discard the throttle body seal.

    Click image to see an enlarged view

    Fig. Exploded view of throttle body, gasket and intake manifold

  22.  

To install:


CAUTION
Wear safety glasses in order to avoid eye damage.

  1. Clean the gasket surface on the intake manifold.
  2.  
  3. Install the throttle body assembly with a new seal.
  4.  
  5. Install the throttle body assembly retaining studs.
    1. Tighten the studs to 80 inch lbs. (9 Nm).
    2.  

  6.  
  7. Install the air cleaner outlet resonator adapter stud.
    1. Tighten the studs to 71 inch lbs. (8 Nm).
    2.  

  8.  
  9. Connect the TP sensor harness connector.
  10.  
  11. Connect the IAC valve harness connector.
  12.  
  13. Install the accelerator control cable bracket using the fasteners.
    1. Tighten the fasteners to 106 inch lbs. (12 Nm).
      WARNING
      Ensure the accelerator and the cruise control cables do not hold the throttle open.

    2.  

  14.  
  15. Install the accelerator cable.
  16.  
  17. Install the cruise control cable.
  18.  
  19. Install the air cleaner outlet resonator.
  20.  
  21. Install the engine cover.
  22.  
  23. Connect the negative battery cable.
    WARNING
    The accelerator pedal should operate freely without binding between full and closed throttle.

  24.  
  25. Use the following procedure in order to check the accelerator pedal operation.
    1. Depress the pedal to the floor.
    2.  
    3. Release the accelerator pedal.
    4.  

  26.  

 
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