Chrysler Cirrus/Stratus/Sebring/Avenger/Breeze 1995-1998

Throttle Body

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REMOVAL & INSTALLATION



Cirrus, Stratus, Sebring Convertible and Breeze
2.0L AND 2.4L Engines

See Figures 1 and 2

  1. Disconnect the remote negative battery cable from the left strut tower. The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
  2.  
  3. Remove the air cleaner/inlet resonator assembly.
  4.  
  5. Disengage the throttle cable from the throttle lever by relieving tension on the cable and sliding out the cable clasp.
  6.  
  7. Compress the retaining tabs on the cable, then slide the cable end out of the bracket.
  8.  



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Fig. Fig. 1: Disengaging the throttle cable

  1. If equipped with cruise control, also remove the speed control cable from the throttle lever by sliding the clasp out of the hole used for the throttle cable.
  2.  
  3. Disconnect the EVAP purge hose from the base of the throttle body.
  4.  
  5. Remove the 2 screws holding the cable mounting bracket and support bracket.
  6.  
  7. Remove the throttle body mounting bolts.
  8.  
  9. Partially lift the throttle body, detach the IAC motor and TPS electrical connectors, then remove the throttle body from the vehicle.
  10.  



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Fig. Fig. 2: The throttle body gasket is reusable

  1. The rubber O-ring gasket is reusable, so wipe it clean and inspect it. If it's in good condition, you can reinstall it. If not, replace it with a new one.
  2.  

To install:
  1. Attach the IAC motor and TPS electrical connections to the throttle body.
  2.  
  3. Position the throttle body on the intake manifold. Do not tighten the mounting bolts at this time.
  4.  
  5. Attach the cable mounting bracket and support bracket. Secure with the 2 mounting screws, but do not tighten at this time.
  6.  
  7. Tighten the throttle body mounting bolts to 175-225 inch lbs. (19.5-25.5 Nm).
  8.  
  9. Tighten the throttle cable bracket mounting bolts to 85-125 inch lbs. (9.5-14 Nm).
  10.  
  11. Connect the EVAP purge hose to the throttle body.
  12.  
  13. Install the cable housing retainer tabs into the bracket.
  14.  
  15. If equipped with cruise control, rotate the throttle lever forward to the wide open throttle position and slide the speed control cable all the way into the lever.
  16.  
  17. Rotate the throttle lever forward to the wide open position and install the throttle cable.
  18.  
  19. Install the air cleaner/inlet resonator assembly.
  20.  
  21. Connect the negative battery cable.
  22.  

2.5L engine

See Figures 3 through 10

  1. Disconnect the remote negative battery cable from the left strut tower. The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
  2.  
  3. Remove the air cleaner/inlet resonator assembly.
  4.  



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Fig. Fig. 3: Disengage the throttle cable from the throttle lever



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Fig. Fig. 4: Hold the throttle lever to the wide open throttle position, then disengage the cruise control cable, if equipped



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Fig. Fig. 5: Disconnect the EVAP purge hose from the throttle body

  1. Disengage the throttle cable from the throttle lever by relieving tension on the cable and sliding out the cable clasp.
  2.  
  3. If equipped with cruise control, remove the speed control cable from the throttle lever by rotating the lever to the wide open throttle position and sliding the cable clasp out of the hole.
  4.  
  5. Disconnect the EVAP purge hose from the base of the throttle body.
  6.  



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Fig. Fig. 6: Disengage the wiring connector to the TPS ...



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Fig. Fig. 7: ... then disengage the wiring connector to the IAC motor

  1. Disengage the IAC motor and TPS electrical connectors.
  2.  
  3. Unfasten the throttle body mounting bolts.
  4.  
  5. Remove the throttle body from the vehicle. Remove the throttle body gasket and clean the gasket mating surfaces.
  6.  



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Fig. Fig. 8: Loosen the 4 throttle body mounting bolts ...



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Fig. Fig. 9: ... then remove the throttle body from the intake manifold plenum



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Fig. Fig. 10: Remove and inspect the throttle body gasket. If it is in good condition, you can reuse it

To install:
  1. Install a new throttle body gasket, then position the throttle body onto the intake manifold and install the mounting bolts. Tighten the throttle body mounting bolts to 250 inch lbs. (28 Nm).
  2.  
  3. Fasten the IAC motor and TPS electrical connections to the throttle body.
  4.  
  5. Install the cruise control cable first (if equipped), then the throttle cable into the throttle lever.
  6.  
  7. Connect the EVAP purge hose to the throttle body.
  8.  
  9. Install the air cleaner/inlet resonator assembly.
  10.  
  11. Connect the negative battery cable.
  12.  

Sebring Coupe and Avenger

See Figures 11 through 20

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air intake hose to the throttle body. It may be necessary to first remove the battery.
  4.  
  5. Disengage the accelerator cable from the throttle lever by relieving tension on the cable and sliding out the cable clasp.
  6.  
  7. Disconnect the EVAP purge hose from the base of the throttle body.
  8.  



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Fig. Fig. 11: Throttle body assembly-2.0L DOHC engine



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Fig. Fig. 12: Throttle body assembly-2.5L engine

  1. Disengage the IAC motor and TPS electrical connectors.
  2.  
  3. Unfasten the throttle body mounting bolts.
  4.  
  5. Remove the throttle body from the vehicle. Remove the throttle body gasket and clean the gasket mating surfaces.
  6.  

To install:
  1. Install a new throttle body gasket, then position the throttle body onto the intake manifold and install the mounting bolts. Tighten the throttle body mounting bolts to 19-23 ft. lbs. (25-31 Nm).
  2.  
  3. Fasten the IAC motor and TPS electrical connections to the throttle body.
  4.  
  5. Install the accelerator cable into the throttle lever.
  6.  
  7. Connect the EVAP purge hose to the throttle body.
  8.  
  9. Install the air intake hose to the throttle body.
  10.  
  11. If a new throttle body is being installed, the accelerator cable must be adjusted.
  12.  
  13. If not equipped with cruise control, adjust the accelerator cable as follows:
    1. Turn OFF the air conditioning and all lights.
    2.  
    3. Start the engine and allow it to idle until it reaches normal operating temperature.
    4.  
    5. After confirming the idle speed is at the prescribed engine RPM, turn the engine OFF .
    6.  
    7. Check to make sure that the accelerator cable has no sharp kinks in it, then check the inner cable for correct slack. If too much slack exists, loosen the cable adjusting bolts.
    8.  
    9. Move the plate to a position immediately before the throttle lever begins to move, then slightly push the plate toward the throttle body in order to bring the cable slack to the standard value of 0.04-0.08 inches (1-2mm).
    10.  
    11. Tighten the adjusting bolts to 43 inch lbs. (5 Nm).
    12.  
    13. Confirm that the throttle lever stopper touches the fixed SAS.
    14.  

  14.  



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Fig. Fig. 13: Once the cable slack is at the standard value, tighten the adjusting bolts to the specified torque



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Fig. Fig. 14: Confirm that the throttle lever stopper contacts the fixed SAS

  1. If equipped with cruise control, adjust the accelerator cable as follows:
    1. Remove the link cover and inspect the slack of the accelerator, speed control and throttle cables.
    2.  
    3. If there is excessive slack or none at all in any of the cables, loosen, but do not remove, the adjusting bolts and nuts in the throttle lever and each link to release.
    4.  

  2.  



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Fig. Fig. 15: Automatic cruise control accelerator cable adjustment-2.0L DOHC engine



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Fig. Fig. 16: Automatic cruise control accelerator cable adjustment-2.5L engine

    1. Adjust with nut A so that when link A contacts the stopper, accelerator (inner) cable play reaches the standard value:

      Manual transaxle-0-0.04 inches (0-1mm)
       
      Automatic transaxle-0.08-0.12 inches (2-3mm)
       

    2.  




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Fig. Fig. 17: Automatic cruise control throttle cable adjustment-2.0L DOHC engine



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Fig. Fig. 18: Automatic cruise control throttle cable adjustment-2.5L engine

    1. Secure the accelerator cable with the locknut.
    2.  
    3. Adjust with nut B so that when lever B contacts link A, the throttle (inner) cable play reaches the standard value of 0.04-0.08 inches (1-2mm).
    4.  
    5. Secure the throttle cable with the locknut.
    6.  
    7. Tighten the throttle lever-side adjusting bolt.
    8.  




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Fig. Fig. 19: Speed control cable adjustment-2.0L DOHC engine



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Fig. Fig. 20: Speed control cable adjustment-2.5L engine

    1. Hold link C at the position where lever C contacts link B. Secure the speed control cable.
    2.  
    3. Install the link cover.
    4.  


  1. Connect the negative battery cable.
  2.  
  3. Road test the vehicle for proper operation.
  4.  

 
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