Aurora 2001-2003

Throttle Body

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Removal & Installation



2.5L & 4.0L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
    NOTE
    Always turn the ignition OFF when connecting or disconnecting battery cables, battery chargers, or jumper cables. Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.


    NOTE
    The battery is located beneath the rear seat cushion.


    NOTE
    Do not damage the MAF sensor screen. A damaged screen could restrict airflow and lead to a drivability concern.

  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    MAF sensor electrical connector from the MAF sensor
     
    Air cleaner intake duct
     
    PCV valve fresh air tube
     
    Cruise control cable from the accelerator controls cable bracket
     
    Accelerator cable from the accelerator controls cable bracket
     
    Cruise control cable from the throttle body lever
     
    Accelerator control cable from the throttle body lever
     
    Idle air control (IAC) valve electrical connector from the IAC valve
     
    Throttle position (TP) sensor electrical connector from the TP sensor
     
    Fuel feed and return lines from the retainer on the accelerator controls cable bracket
     
    Transaxle shift cable clip from the accelerator controls cable bracket
     
    Throttle body from the water crossover
     
    Accelerator controls cable bracket from the throttle body

    Click image to see an enlarged view

    Fig. Throttle body and bracket layout

     

  8.  

To install:


NOTE
Do not use a cleaner which contains methyl ethyl ketone. This extremely strong solvent may damage components and is not necessary for this type of cleaning. Use a carburetor cleaner in order to remove deposits. Refer to the instructions provided with the cleaner.


NOTE
The outlet of the air cleaner assembly and the MAF sensor inlet duct must line up when completely installed. Misalignment may cause incorrect airflow readings resulting in MIL illumination or a drivability concern. An improperly installed inlet duct assembly or air cleaner assembly may cause misalignment.


NOTE
DO NOT reuse the old throttle body gasket.

  1. Install the throttle body to the water crossover and tighten the bolts to 106 inch lbs. (12 Nm)
  2.  
  3. Position the new throttle body gasket on to the throttle body.
  4.  
  5. Install accelerator control bracket bolts to the throttle body and tighten the bolts to 106 inch lbs. (12 Nm)
  6.  
  7. Install or connect the following:

    IAC valve electrical connector to the IAC valve
     
    TP sensor electrical connector to the TP sensor
     
    Accelerator control cable at the throttle body lever
     
    Cruise control cable at the throttle body lever
     
    Accelerator cable to the accelerator controls cable bracket
     
    Cruise control cable to the accelerator controls cable bracket
     
    Transaxle shift cable clip to the accelerator controls cable bracket
     
    Fuel feed and return lines from the retainer on to the accelerator controls cable bracket
     
    MAF sensor electrical connector to the MAF sensor
     
    Air cleaner intake duct clamp to the air cleaner intake air duct and tighten the clamps to 27 inch lbs. (3 Nm)
     
    PCV valve fresh air tube
     
    Fuel injector sight shield and tighten the nuts to 20 inch lbs. (2.3 Nm)
     

  8.  
  9. Reconnect the negative battery cable and reinstall the rear seat cushion.
  10.  

3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
    NOTE
    Always turn the ignition OFF when connecting or disconnecting battery cables, battery chargers, or jumper cables. Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.


    NOTE
    The battery is located beneath the rear seat cushion.


    NOTE
    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.

  4.  
  5. Turn OFF the ignition.
  6.  
  7. Remove the fuel injector sight shield.
  8.  
  9. Drain the radiator coolant.
  10.  
  11. Remove the air cleaner intake duct.
  12.  
  13. Disconnect the Idle Air Control (IAC) valve sensor electrical connector.
  14.  
  15. Disconnect the Throttle Position (TP) sensor electrical connector.
  16.  
  17. Disconnect the cruise control cable from the throttle body lever.
  18.  
  19. Disconnect the accelerator control cable from the throttle body lever.
  20.  
  21. Disconnect the fuel pressure regulator vacuum hose.
  22.  
  23. Disconnect the Positive Crankcase Ventilation (PCV) valve hose.
  24.  
  25. Disconnect the throttle body vacuum port hose.
  26.  
  27. Disconnect the throttle body coolant hoses.
  28.  
  29. Remove the accelerator controls cable bracket, leaving the accelerator and cruse cables connected.
  30.  
  31. Remove the upper nut holding the throttle body to the intake manifold.
  32.  
  33. Remove the throttle body assembly.
  34.  
  35. Clean the gasket surface on the intake manifold and the throttle body assembly.

    Click image to see an enlarged view

    Fig. Throttle body and gasket orientation

  36.  

To install:


NOTE
The throttle should operate freely without binding between full closed and wide open throttle.

  1. Install or connect the following:

    New gasket and studs, if necessary.
     
    Throttle body assembly and finger-start the top nut.
     
    Throttle body coolant hoses
     

  2.  
  3. Position the accelerator controls bracket and finger start the nuts and bolt.
  4.  
  5. Tighten as follows:
    1. Tighten the three throttle body retaining nuts to 89 inch lbs. (10 Nm)
    2.  
    3. Tighten the accelerator bracket retaining bolt to 115 inch lbs. (13 Nm)
    4.  

  6.  
  7. Continue connecting or installing:

    Throttle body vacuum port hose
     
    PCV valve hose
     
    Fuel pressure regulator vacuum hose
     
    Accelerator controls cable to the throttle body lever
     
    Cruise control cable to the throttle body lever
     
    IAC valve sensor electrical connector
     
    TP sensor electrical connector
     
    Air intake duct
     

  8.  
  9. Refill the radiator to replace the lost coolant.
  10.  
  11. Install the fuel injector sight shield.
  12.  
  13. Reconnect the negative battery cable and reinstall the rear seat cushion.
  14.  

 
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