Cavalier, Sunfire 2001-2005

Throttle Body

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Removal & Installation



2.2L (VIN 4) Engine

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.


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


CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF , unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner resonator from the throttle body.
  4.  
  5. Remove the electrical connector from the Idle Air Control (IAC) valve.
  6.  
  7. Remove the electrical connector from the Throttle Position (TP) sensor.
  8.  
  9. Remove the vacuum hoses at the throttle body.
  10.  
  11. Remove the accelerator cable and the cruise control cable from the throttle body and bracket, if the vehicle is so equipped..
  12.  
  13. Remove the accelerator cable bracket.

    Click image to see an enlarged view

    Fig. Remove the throttle body attaching bolts (2) and the throttle body (1) from the intake manifold

  14.  
  15. Remove the throttle body attaching bolts.
  16.  
  17. Remove the throttle body from the intake manifold.
  18.  

To install:

  1. Inspect the throttle body gasket and replace if necessary.
  2.  
  3. Install the throttle body.
  4.  
  5. Install the accelerator cable bracket.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  6.  
  7. Install the throttle body attaching bolts and tighten the throttle body attaching bolts to 89 lb inches (10 Nm).
  8.  
  9. Install the accelerator cable and the cruise control cable, if the vehicle is so equipped, to the throttle body.
  10.  
  11. Install the vacuum hoses to the throttle body.
  12.  
  13. Install the electrical connector to the TP sensor.
  14.  
  15. Install the electrical connector to the IAC valve.
  16.  
  17. 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 the pedal.

  18.  
  19. Connect the negative battery cable.
  20.  
  21. Reset the IAC valve pintle position as follows:
  22.  
  23. Turn ON the ignition.
  24.  
  25. Turn OFF the ignition for ten seconds.
  26.  
  27. Start the engine and check for proper idle operation.
  28.  

2.2L (VIN F) Engine

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.


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



Click image to see an enlarged view

Fig. Remove the throttle body (4) from the intake manifold

  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.
  12.  
  13. Remove the throttle body from the intake manifold.
  14.  

To install:

  1. Inspect the throttle body gasket and replace if necessary.
  2.  
  3. Install the throttle body to the intake manifold.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4.  
  5. Install the throttle body attaching bolts and studs and tighten the throttle body attaching bolts and studs to 89 lb inch (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

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.


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


CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF , unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner outlet resonator.
  4.  
  5. Disconnect the Idle Air Control (IAC) valve harness connector .
  6.  
  7. Disconnect the Throttle Position (TP) sensor harness connector .

    Click image to see an enlarged view

    Fig. Remove the vacuum hoses at the throttle body

  8.  
  9. Remove the vacuum hoses at the throttle body.
  10.  
  11. Remove the accelerator and cruise control cables.
  12.  
  13. Remove the accelerator cable bracket.

    Click image to see an enlarged view

    Fig. Remove the throttle body attaching bolts (1)

  14.  
  15. Remove the throttle body attaching bolts.
  16.  
  17. Remove the Manifold Absolute Pressure (MAP) sensor.
  18.  
  19. Remove the throttle body from the intake manifold.
  20.  

To install:


NOTE
The EVAP canister may have released carbon particles which caused this part to fail and may cause damage to other components. Check the EVAP canister for loose carbon before returning the vehicle to service.

  1. Install the throttle body.
  2.  
  3. Install the accelerator cable bracket.
  4.  
  5. Install the MAP sensor.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  6.  
  7. Install the throttle body attaching bolts and tighten the throttle body and MAP sensor attaching bolts to 89 lb inches (10 Nm).
  8.  
  9. Install the accelerator and cruise control cables to throttle body.
  10.  
  11. Install the vacuum hoses to throttle body.
  12.  
  13. Install the electrical connector to the IAC valve.
  14.  
  15. Connect the electrical connector to the TP sensor.
  16.  
  17. Connect the air cleaner outlet resonator.
    NOTE
    With the engine OFF , check to see that the accelerator pedal is free, by depressing the pedal to the floor and releasing.

  18.  
  19. Connect the negative battery cable.
  20.  
  21. Reset IAC valve pintle position:


    1. Turn ON the ignition.
    2.  
    3. Turn OFF the ignition for ten seconds
    4.  
    5. Start the engine and check for proper idle operation
    6.  

  22.  

 
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