Chrysler Full-Size Trucks 1989-1996 Repair Guide

Throttle Body

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REMOVAL & INSTALLATION



See Figures 1 through 15

  1. Remove the air cleaner.
  2.  
  3. Perform the fuel system pressure release.
  4.  
  5. Disconnect the negative battery cable.
  6.  



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Fig. Fig. 1: A common dual point throttle body prior to removal-1990 3.9L engine shown



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Fig. Fig. 2: You may wish to clamp the fuel lines to prevent any dripping



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Fig. Fig. 3: Disconnect the barrel end of the throttle cable and position it out of the way



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Fig. Fig. 4: Remove the return spring from the throttle body-1990 3.9L engine shown



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Fig. Fig. 5: Be careful not to lose any small parts such as this washer and retaining clip



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Fig. Fig. 6: Remove the transmission kickdown rod link, if equipped-1990 3.9L engine shown



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Fig. Fig. 7: Disconnect the fuel hoses and set them aside. If mix-up is possible, tag them first



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Fig. Fig. 8: Unbolt the throttle body from the manifold



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Fig. Fig. 9: Remove the bolts and set them in a safe place with the other related hardware



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Fig. Fig. 10: Remove the throttle body and set it in a clean, safe location



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Fig. Fig. 11: Remove the old gasket and discard it



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Fig. Fig. 12: Stuff a clean rag into the manifold to prevent the entry of dirt or other foreign material



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Fig. Fig. 13: Common V6 engine throttle body components



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Fig. Fig. 14: Exploded view of throttle body mounting-V6 engine shown; others similar



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Fig. Fig. 15: Common V8 engine throttle body components

  1. Disconnect the vacuum hoses and electrical connectors. Tag as necessary any hoses/connectors to ease installation.
  2.  
  3. Disconnect the throttle cable and, if so equipped, speed control and kickdown cables/rod.
  4.  
  5. Remove the return spring, if applicable.
  6.  
  7. Disconnect the fuel intake and return hoses.
  8.  
  9. Remove the throttle body mounting bolts and lift the throttle body from the engine.
  10.  

To install:
  1. When installing the throttle body, use a new gasket. Position the throttle body and tighten the mounting screws to 15 ft. lbs. (20 Nm).
  2.  
  3. Connect the fuel intake and return hoses using new original equipment type clamps.
  4.  
  5. Install the return spring.
  6.  
  7. Attach the throttle cable and, if so equipped, attach the kickdown and speed control cables.
  8.  
  9. Engage the wiring connectors and vacuum hoses.
  10.  
  11. Install the air cleaner.
  12.  
  13. Reconnect the negative battery cable.
  14.  

 
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