Ford Freestar, Monterey 2004-2006

Throttle Body

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Removal & Installation




WARNING
Throttle body bore and plate area have a special coating and cannot be cleaned, or possible damage to the throttle body can occur.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner outlet pipe.
  4.  
  5. Detach the harness retainer from the cable bracket stud bolt.
  6.  
  7. Disconnect the Throttle Position (TP) sensor electrical connector.
  8.  
  9. Disconnect the throttle return spring from the throttle body.
  10.  
  11. Disconnect the speed control cable from the throttle body.
  12.  
  13. Disconnect the accelerator cable from the throttle body.
  14.  
  15. Remove the 2 cable bracket bolts and position the bracket and cables aside.
  16.  
  17. Remove the 4 throttle body-to-upper intake manifold bolts and the throttle body.
  18.  
  19. Remove the throttle body gasket.
  20.  
  21. Inspect the gasket and install new if necessary.

    Click image to see an enlarged view

    Fig. Exploded view of the harness retainer (1), TP sensor connector (2), throttle return spring (3), speed control cable (4), accelerator cable (5), cable bracket bolts (6), cable bracket (7), throttle body-to-intake manifold bolts (8), throttle body (9) and gasket (10)

  22.  

To install:

  1. Install the throttle body gasket and throttle body. Tighten the mounting bolts to 89 inch lbs. (10 Nm).
  2.  
  3. Install the cable bracket and tighten the bolts to 11 ft. lbs. (15 Nm).
  4.  
  5. Attach the accelerator cable to the throttle body.
  6.  
  7. Connect the speed control cable to the throttle body.
  8.  
  9. Connect the throttle return spring to the throttle body.
  10.  
  11. Attach the TP sensor electrical connector.
  12.  
  13. Attach the harness retainer to the cable bracket stud bolt.
  14.  
  15. Install the air cleaner outlet pipe.
  16.  
  17. Connect the negative battery cable.  
  18.  

 
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