Cobalt 2006-2008, G5 2007

Throttle Body

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
    WARNING
    Do not use solvents 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. Solvents that contain Methyl Ethyl Ketone (MEK) may damage fuel system components.

  2.  
  3. Remove the air cleaner outlet duct.
  4.  
  5. Disconnect the Evaporative Emission (EVAP) purge line.
  6.  
  7. Disconnect the throttle body control harness connector.
  8.  
  9. Remove the throttle body attaching bolts.
  10.  
  11. Remove the throttle body and gasket from the supercharger.

    Click image to see an enlarged view

    Fig. Removing the throttle body-2.0L Engine

  12.  

To install:

  1. Inspect the throttle body gasket and replace if necessary.
  2.  
  3. Install the throttle body to the supercharger.
  4.  
  5. Install the throttle body attaching bolts. Tighten the throttle body attaching bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Connect the throttle body control harness connector.
  8.  
  9. Connect the EVAP purge line.
  10.  
  11. Install the air cleaner outlet duct.
  12.  

2.2L & 2.4L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
    WARNING
    Do not use solvents 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. Solvents that contain Methyl Ethyl Ketone (MEK) may damage fuel system components.


    NOTE
    DO NOT prop open the throttle blade with the ignition key in the ON position as it may set a Diagnostic Trouble Code (DTC).

  2.  
  3. Remove the air cleaner outlet duct.
  4.  
  5. Remove the intake manifold cover:
    1. Remove the engine oil fill cap.
    2.  
    3. Grasp the intake manifold cover by the lower right inboard corner and pull up to disengage the cover from the stud.
    4.  
    5. Grasp the intake manifold cover by the upper left corner and pull up to disengage the cover from the stud.
    6.  
    7. Remove the intake manifold cover.

      Click image to see an enlarged view

      Fig. Location of the Throttle Actuator Control (TAC) electrical connector (1)

    8.  

  6.  
  7. Disconnect the Throttle Actuator Control (TAC) electrical connector (1).
  8.  
  9. Remove the throttle body bolts.
  10.  
  11. Remove the throttle body.

    Click image to see an enlarged view

    Fig. Removing the throttle body-2.2L & 2.4L Engines

  12.  

To install:

  1. Inspect the throttle body gasket, and replace if necessary.
  2.  
  3. Install the throttle body.
  4.  
  5. Install the throttle body bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Connect the TAC electrical connector (1).
  8.  
  9. Install the intake manifold cover:
    1. Place the intake manifold cover onto the engine over the studs.
    2.  
    3. Push down on the intake manifold cover directly over the lower right stud in order to engage the cover to the stud.
    4.  
    5. Push down on the intake manifold cover directly over the upper left stud in order to engage the cover to the stud.
    6.  
    7. Install the engine oil fill cap.
    8.  

  10.  
  11. Install the air cleaner outlet duct.
  12.  

 
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