See Figures 1, 2 and 3
REMOVAL & INSTALLATION
The throttle body for each of the engines is slightly different. The procedure below is general and may require slight alteration of sequence depending on the engine.
- Disconnect the negative battery cable.
- Drain the coolant, at least to a level below the intake manifold.
- Disconnect the main air intake duct from the throttle body.
- Label and disconnect the vacuum and breather hoses running to the throttle body. Take care that clamps are not bent or distorted during removal.
- Disconnect the accelerator cable and the cruise control cable if so equipped. On some engines, the bracket holding the cable to the intake manifold must be removed.
- Label and disconnect the coolant hoses running to the throttle body.
- Follow each wire running from the throttle body. Label and disconnect each at its connector. Most of the wiring harnesses have connectors at some distance from the throttle body. Loosen, release or remove any clips or brackets holding the throttle body harnesses in place.
- Carefully remove the four nuts and bolts holding the throttle body to the manifold. On 1.6L, the throttle body is supported by a bracket which must be removed before the throttle body can be removed.
Some throttle bodies have the idle speed control servo assembly mounted on the top of the unit. The large bracket may appear to be holding the throttle body in place. It should not be removed from the throttle body.
- Lift the throttle body away from the manifold and handle it carefully. Place it in a protected location.
- If the unit is being replaced, compare the old and the new ones. Look for any components which need to be transferred from the old unit. The throttle plate area may be cleaned with a spray cleaner, but must be completely dry before installation. Disassembly of the throttle body is not recommended.
- Before reinstalling, make sure that all remains of the old gasket are removed from both the manifold flange and the base of the throttle body. Place a new gasket on the manifold and hold the throttle body in place. Don't forget the support bracket on the twin cam engines.
- Install the four nuts and bolts finger tight. Tighten the bolts evenly, alternating from bolt to bolt, in small increments. The bolts must draw down evenly, creating an airtight seal against the gasket.
- Tighten the nuts and bolts to 11 Nm (8 ft. lbs.). The bracket bolt or nut is tightened to the same figure.
- Reconnect the wiring connectors to the harnesses. Secure, tighten or reinstall any wire clips or retainers. The harnesses must be kept clear of moving or hot surfaces.
- Install the coolant hoses, making sure each is properly clamped to its port.
- Install the accelerator cable and cruise control cable if so equipped. Adjust the cable to the correct tension and make certain the lock nuts or bracket bolts are secure.
- Connect the vacuum hoses. Examine the end of each and replace any showing signs of cracking or hardening.
- Install the main air duct and connect the breather tubes.
- Refill the coolant to the proper level.
- Connect the negative battery cable.