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    Ford Aerostar 1986-1997 Repair Guide

    Throttle Body

    Print

    REMOVAL & INSTALLATION



    2.3L Engine

    See Figures 1, 2 and 3

    1. Disconnect the negative battery cable.
    2.  
    3. Remove the throttle linkage shield.
    4.  
    5. Disconnect the throttle linkage and cruise control.
    6.  
    7. Unbolt the accelerator cable from the bracket.
    8.  



    Click image to see an enlarged view

    Fig. Fig. 1: Throttle body assembly-2.3L engine

    1. Tag and disconnect the wiring at the throttle position sensor and air bypass valve.
    2.  
    3. Disconnect the air intake hose from the throttle body.
    4.  
    5. Disconnect the PCV and canister purge hoses.
    6.  
    7. Remove the 4 throttle body-to-upper intake manifold bolts and lift off the throttle body. Discard the gasket.
    8.  
    9. Clean all gasket material from the mating surfaces.
    10.  



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    Fig. Fig. 2: Remove the retainer bolts securing the throttle body to the intake manifold



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    Fig. Fig. 3: Throttle body on gasket separated from the intake manifold

    To install:
    1. Position the throttle body and new gasket on the manifold. Hand start the bolts, then tighten them, evenly, to 15-25 ft. lbs. (19-32 Nm).
    2.  
    3. Connect the PCV and canister hoses.
    4.  
    5. Connect the air intake hose.
    6.  
    7. Connect the wiring to the throttle position sensor and air bypass valve.
    8.  
    9. Connect the throttle and cruise control linkages.
    10.  
    11. Connect the negative battery cable.
    12.  

    3.0L Engine

    See Figures 4 through 12

    The 3.0L throttle body is cast to the upper intake manifold assembly. To remove the throttle body, the entire upper intake manifold assembly must be removed.

    1. Disconnecting the negative battery cable.
    2.  
    3. Remove the air cleaner outlet tube.
    4.  
    5. Remove the snow shield by removing the plastic retainer clips.
    6.  
    7. Tag and disconnect the vacuum and PCV hoses.
    8.  
    9. Disconnect and remove the accelerator and speed control cables (if equipped) from the accelerator mounting bracket and throttle lever.
    10.  
    11. Tag and disconnect the wiring harness at the throttle position sensor, air bypass valve and air charge temperature sensor.
    12.  



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    Fig. Fig. 4: Throttle body assembly-3.0L engine



    Click image to see an enlarged view

    Fig. Fig. 5: Tag and disconnect the vacuum lines attached to the manifold/throttle body assembly



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    Fig. Fig. 6: Some vacuum lines are secured in place with clamps. These clamps must be removed or loosened



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    Fig. Fig. 7: Loosen the manifold/throttle body retainer bolts



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    Fig. Fig. 8: Lift the bolts out and place aside



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    Fig. Fig. 9: lift the manifold/throttle body assembly off the lower manifold



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    Fig. Fig. 10: Remove and discard the gasket between the manifold sections



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    Fig. Fig. 11: Place rags in the intake chamber to prevent debris from falling in



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    Fig. Fig. 12: With the chambers covered, clean any remaining gasket material from the mating surface

    1. Remove the retaining bolts and stud bolts and lift the throttle body assembly off the lower intake manifold.
    2.  
    3. Remove and discard the gasket. Clean all gasket material from the mating surfaces.
    4.  

    To install:
    1. Install a new gasket on the lower intake manifold.
    2.  
    3. Install the air throttle body assembly on the lower intake manifold.
    4.  
    5. Install the bolts finger-tight, then tighten them evenly to 19 ft. lbs. (25 Nm).
    6.  
    7. Connect the wiring harness to the throttle position sensor, air charge temperature sensor and air bypass valve.
    8.  
    9. Install the accelerator cable and speed control cable, if equipped.
    10.  
    11. Install the vacuum hoses to the vacuum fittings, making sure the hoses are installed in their original locations.
    12.  
    13. Install the snow shield and air cleaner outlet tube.
    14.  
    15. Connect the negative battery cable.
    16.  

    4.0L Engine

    See Figure 13

    1. Disconnect the negative battery cable.
    2.  
    3. Remove the air cleaner inlet tube.
    4.  
    5. Remove the snow shield.
    6.  
    7. Disconnect the throttle cable at the ball stud.
    8.  
    9. Unfasten the canister purge hose from under the throttle body.
    10.  
    11. Disconnect the wiring harness at the throttle position sensor.
    12.  
    13. Remove the retaining bolts, then lift the throttle body assembly off the upper intake manifold.
    14.  
    15. Remove and discard the gasket.
    16.  



    Click image to see an enlarged view

    Fig. Fig. 13: Throttle body and intake manifold assembly-4.0L engine

    To install:
    1. Clean and inspect the mounting faces of the throttle body assembly and the upper intake manifold. Both surfaces must be clean and flat.
    2.  
    3. Install a new gasket on the manifold.
    4.  
    5. Install the air throttle body assembly on the intake manifold.
    6.  
    7. Install the bolts finger-tight, then tighten them evenly to 76-106 inch lbs. (8-12 Nm).
    8.  
    9. Fasten the wiring harness to the throttle position sensor.
    10.  
    11. Install the canister purge hose.
    12.  
    13. Install the snow shield and air cleaner outlet tube.
    14.  
    15. Connect the negative battery cable.
    16.  

    PARTS REPLACEMENT Air Bypass Solenoid Valve

    See Figure 14

    The air bypass solenoid valve or idle control valve as it is sometimes referred to is attached to the side or top of the throttle body. Refer to Emission Controls of this guide for test and removal and installation procedures on air bypass solenoid valves.



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    Fig. Fig. 14: Air bypass solenoid-2.3L engine

    Throttle Position Sensor

    See Figure 15

    The throttle position sensor attached to the side or top of the throttle body is responsible for idle speed control. Refer to Emission Controls of this guide for test and removal and installation procedures on air bypass solenoid valves.



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    Fig. Fig. 15: Throttle position sensor attached to the side of the throttle body

    ADJUSTMENTS



    Throttle Plate
    1. Start vehicle and allow it to reach normal operating temperature.
    2.  
    3. Connect a tachometer according to the tachometer manufacturer's specification.
    4.  

    When adjusting throttle plate position, perform service in a well ventilated area.

    1. Access the adjuster screw hole from the rear of the throttle body. To increase the idle, turn screw clockwise. To lower the idle, turn screw counterclockwise. Refer to the vehicle emission sticker in the engine compartment to determine the correct idle speed.
    2.  
    3. Turn the adjuster screw until the correct idle speed is reached.
    4.  

     
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