Chrysler Full-Size Vans 1989-1998 Repair Guide

Throttle Body

Print

REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12 and 13

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine cover.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Disconnect and label the vacuum hoses and electrical connectors.
  8.  
  9. Remove the throttle and kickdown cables and if so equipped, the speed control cable.
  10.  
  11. Remove the throttle body mounting screws and lift the throttle body from the engine.
  12.  

To install:
  1. Thoroughly clean the intake manifold and the throttle body gasket surfaces.
  2.  
  3. When installing the throttle body, use a new gasket. Install the throttle body and tighten the mounting screws to 200 inch lbs. (23 Nm).
  4.  
  5. Install the throttle and kickdown cables and, if so equipped, the speed control cable.
  6.  
  7. Install the wiring connectors and vacuum hoses.
  8.  
  9. Install the air cleaner assembly.
  10.  
  11. Reconnect the negative battery cable.
  12.  
  13. Start the engine and check for leaks.
  14.  
  15. Install the engine cover.
  16.  



Click image to see an enlarged view

Fig. Fig. 1: Remove the vacuum line to the throttle body



Click image to see an enlarged view

Fig. Fig. 2: Separate the electrical connector from the IAC valve



Click image to see an enlarged view

Fig. Fig. 3: Unfasten the electrical connector from the TP sensor



Click image to see an enlarged view

Fig. Fig. 4: Detach the electrical connector from the MAP sensor



Click image to see an enlarged view

Fig. Fig. 5: Squeeze the tabs on the transmission kickdown cable and pull it through the bracket



Click image to see an enlarged view

Fig. Fig. 6: Remove the throttle cable from the bracket



Click image to see an enlarged view

Fig. Fig. 7: Disconnect the transmission kickdown cable by pushing it forward to release from the eyelet



Click image to see an enlarged view

Fig. Fig. 8: Disconnect the throttle cable barrel end from the throttle body



Click image to see an enlarged view

Fig. Fig. 9: Remove the bolts retaining the throttle body to the intake manifold



Click image to see an enlarged view

Fig. Fig. 10: Remove the throttle body from the intake manifold



Click image to see an enlarged view

Fig. Fig. 11: Placing a rag in the port for the throttle body will reduce the chance of something falling into the intake manifold



Click image to see an enlarged view

Fig. Fig. 12: Thoroughly clean the gasket surface before reinstalling the throttle body



Click image to see an enlarged view

Fig. Fig. 13: Install a new gasket on the intake manifold, and remove the rag blocking the port, before reinstalling the throttle body

 
label.common.footer.alt.autozoneLogo