Breeze, Cirrus, Sebring Convertible and Sedan, Stratus Sedan, 1999-2005

Throttle Body

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Removal & Installation




NOTE
Before servicing the vehicle, also refer to the precautions in the beginning of this section.

2.0L & 2.4L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Remove or disconnect the following:

    Air inlet resonator.
     
    Throttle control shield.
     

  6.  
  7. Remove throttle cable from the throttle body lever.
    1. Compress the retaining tabs on the cable and slide cable out of bracket.
    2.  
    3. If equipped with speed control, remove speed control cable from throttle lever by sliding clasp out hole used for throttle cable.

      EVAP purge hose from nipple on throttle body.
       
      2 screws holding cable mounting bracket and support bracket.
       
      Throttle body mounting bolts.
       

    4.  

  8.  
  9. Lift throttle body far enough to remove connectors from the throttle position sensor and idle air control motor.
  10.  
  11. Remove throttle body.
  12.  

To install:

The rubber O-ring gasket on the 2.0L engine's intake manifold is reusable. Wipe the O-ring clean before installing throttle body. 2.4L Requires a new paper gasket.

  1. Attach electrical connectors to idle air control motor and throttle position sensor.
  2.  
  3. Install new paper gasket (2.4L engine)
  4.  
  5. Position throttle body on intake and install mounting bolts. Do not tighten the bolts at this time.
  6.  
  7. Install throttle cable bracket. Do not tighten the bolts at this time.
  8.  
  9. Tighten throttle body bolts to 200 inch lbs. (22.5 Nm)
  10.  
  11. Tighten throttle cable bracket bolts to 105 inch lbs. (12 Nm)
  12.  
  13. Install or connect the following:

    EVAP purge hose to throttle body nipple.
     
    Cable housing retainer tabs into bracket.
     
    Throttle body cables by rotating the throttle lever forward to the wide open position.
     
    Air inlet resonator.
     
    Throttle control shield and torque the screw to 50 inch lbs. (6 Nm)
     

  14.  

  1. Disconnect negative cable from battery cable.
  2.  
  3. Remove the clean air hose.
  4.  
  5. Remove the throttle cable shield.
  6.  
  7. Remove the throttle and the speed control cables (if equipped) from lever and bracket.
  8.  
  9. Disconnect the electrical connectors from the idle air control motor and Throttle Position Sensor (TPS).
  10.  
  11. Remove the throttle body to intake manifold attaching bolts.
  12.  
  13. Remove the throttle cable bracket.
  14.  
  15. Remove the throttle body.
  16.  

To install:

  1. Install the throttle body.
    1. Tighten throttle body mounting bolts to 120 inch lbs. (13.6 Nm).
    2.  

  2.  
  3. Install the throttle cable bracket.
    1. Tighten throttle cable bracket mounting bolts to 125 inch lbs. (14.1 Nm)
    2.  

  4.  
  5. Hold throttle lever in the wide open throttle position and install the throttle and speed control cables (if equipped).
  6.  
  7. Connect the electrical connectors to the idle air control motor and Throttle Position Sensor (TPS).
  8.  
  9. Install the throttle cable shield.
  10.  
  11. Install the clean air hose to throttle body.
  12.  
  13. Connect negative cable to battery cable.

    Click image to see an enlarged view

    Fig. Throttle body-2.0L and 2.4L engines

  14.  

2.5L & 3.0L Engines

CAUTION
This operation must only be done on a cold engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Drain engine coolant Remove or disconnect the following:

    Air cleaner and housing
     
    Throttle cable from the throttle body lever
     
    Throttle position sensor (TPS) connector
     
    Idle air control motor connector
     
    Vacuum hose (2 hoses if equipped with cruise control)
     
    Throttle body stay
     
    Throttle body
     
    Throttle body gasket
     

  6.  
  7. Daimler-Chrysler also recommends inspecting the electrical resistance of the throttle body while it is removed.
    1. Connect an ohmmeter between terminals 1 (ground) and 3 (output), or between terminals 3 (output) and 4 (power). Then, make sure the resistance changes smoothly when the throttle valve is slowly moved to the fully open position.
    2.  

  8.  
  9. Install or connect the following:
    NOTE
    If the throttle body gasket is improperly installed, the engine will not idle correctly.



    Throttle body with a new gasket and torque the bolts to 14 ft. lbs. (19 Nm)
     



    Throttle body stay and torque the bolts to 14 ft. lbs. (19 Nm)
     
    Vacuum hoses
     
    Idle air control motor connector
     
    Throttle position sensor connector
     
    Accelerator cable
     
    Air cleaner and housing
     
    Refill the cooling system
     

  10.  
  11. Start the engine and bring it up to operating temperature
  12.  
  13. Using the adjusting bolts on the throttle cable bracket attached to the intake manifold, adjust the cable so that the engine idles at 600-800 rpm.
  14.  
  15. Shut off the engine and work the throttle pedal through its entire range to make sure the throttle body opens and closes fully.
  16.  

2.5L Engine
  1. Remove the negative battery cable.
  2.  
  3. Remove the air tube from throttle body.
  4.  
  5. Remove the throttle cable from the throttle body lever.
  6.  
  7. Push release tang toward dash panel on throttle cable and slide cable out of bracket
  8.  
  9. Slide speed control cable out of bracket (if equipped).
  10.  
  11. Remove the EVAP purge hose from nipple on throttle body.
  12.  
  13. Remove the connectors from throttle position sensor and idle air control motor.
  14.  
  15. Remove the bolts holding throttle body to intake manifold. Remove throttle body
  16.  

To install:

  1. Attach electrical connectors to idle air control motor and throttle position sensor.
  2.  
  3. Install the new gasket.
  4.  
  5. Position throttle body on intake and install the mounting bolts.
    1. Tighten bolts to 21 ft. lbs. (28.25 Nm)
    2.  

  6.  
  7. Install the speed control cable (if equipped) and throttle cable into throttle lever.
  8.  
  9. Install the cables into cable bracket.
  10.  
  11. Install the air inlet tube.
    1. Tighten clamps to 25 inch lbs. (3 Nm).
    2.  

  12.  
  13. Install the negative battery cable.
  14.  

2.7L Engine
  1. Disconnect negative cable from battery
  2.  
  3. Disconnect the electrical connectors from throttle body.
  4.  
  5. Disconnect clean air hose from throttle body.
  6.  
  7. Remove the throttle cable shield.
  8.  
  9. Hold throttle lever in wide open position. Remove throttle cable and speed control cables from throttle arm.
  10.  
  11. Remove the throttle cable bracket.
  12.  
  13. Remove the throttle body support bracket from the bottom of the throttle body.
  14.  
  15. Remove the remaining 2 throttle body bolts.
  16.  
  17. Remove the throttle body.
  18.  
  19. Clean mating surfaces.

    Click image to see an enlarged view

    Fig. Throttle body-2.7L engine

  20.  

To install:

  1. Loose Install the 2 throttle body bolts (upper right and lower bolt).
  2.  
  3. Install the throttle cable bracket.
  4.  
  5. Install the third throttle body bolt and the throttle body support bracket to the bottom of the throttle body.
    1. Tighten the lower support bracket bolts to 23 ft. lbs. (31.1 Nm)
    2.  
    3. Tighten throttle body bolts to 120 inch lbs. (13.6 Nm).
    4.  

  6.  
  7. Hold throttle lever in wide open throttle position. Install the throttle cable and speed control cable.
  8.  
  9. Install the throttle cable shield.
  10.  
  11. Connect the electrical connectors to throttle body.
  12.  
  13. Install the clean air hose to throttle body.
  14.  
  15. Connect negative cable to battery.
  16.  

 
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