GM Cavalier/Sunfire 1995-2000 Repair Guide

Throttle Body

Print

REMOVAL & INSTALLATION



2.3L Engine

See Figures 1 and 2



Click image to see an enlarged view

Fig. Fig. 1: View of the throttle body including the TP sensor and IAC valve-1995 2.3L (VIN D) engine shown

The TP sensor and IAC valve should NOT come into contact with any type of solvent or cleanser, as this may cause damage.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air cleaner cover and air duct.
  6.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the throttle body mounting

  1. Partially drain the coolant to allow the coolant hoses at the throttle body to be removed.
  2.  
  3. Disconnect the vacuum hose from the fuel pressure regulator.
  4.  
  5. Detach the electrical connectors from the TP sensor and IAC valve.
  6.  
  7. Disconnect the throttle, transaxle control and cruise control (if equipped) cables.
  8.  
  9. Unfasten the throttle body attaching bolts, then loosen the throttle body from the intake manifold.
  10.  
  11. Disconnect the coolant hoses from the throttle body.
  12.  
  13. Detach the vacuum hose from the bottom of the throttle body.
  14.  
  15. Remove the throttle body and gasket. Discard the gasket.
  16.  

To install:
  1. Connect the vacuum hose to the bottom of the throttle body.
  2.  
  3. Fasten the coolant hoses to the throttle body.
  4.  
  5. Position the throttle body, with a new gasket, against the manifold, then secure with the attaching bolts. Tighten the bolts to 11 ft. lbs. (15 Nm).
  6.  
  7. Fasten the throttle, cruise control and transaxle cables to the throttle body.
  8.  
  9. Attach the TP sensor and IAC valve electrical connectors.
  10.  
  11. Connect the vacuum hose to the fuel pressure regulator.
  12.  
  13. Refill the cooling system to the proper level.
  14.  
  15. Install the air duct and air cleaner cover.
  16.  
  17. Connect the negative battery cable.
  18.  

2.4L Engine and 1998-00 2.2L Engine

See Figures 3 and 4



Click image to see an enlarged view

Fig. Fig. 3: Throttle body assembly mounting-1998-00 2.2L engine



Click image to see an enlarged view

Fig. Fig. 4: Throttle body assembly mounting-2.4L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner resonator and outlet hose from the vehicle.
  4.  
  5. Detach the connectors for the TP sensor and IAC valve.
  6.  
  7. Remove the vacuum hoses from the throttle body.
  8.  
  9. Remove the throttle, cruise (if equipped), and transmission control (automatic transaxles only) cables from the throttle body.
  10.  
  11. On the 2.4L engine, remove the MAP sensor.
  12.  
  13. Remove the accelerator cable bracket.
  14.  
  15. Remove the throttle body attaching bolts.
  16.  
  17. Remove the throttle body from the intake manifold.
  18.  

To install:
  1. Thoroughly clean the throttle body and intake manifold mounting surfaces.
  2.  
  3. Install the throttle body onto the intake manifold.
  4.  
  5. Tighten the throttle body retaining bolts to 89 inch lbs. (10 Nm) on the 2.2L engine and 58 inch lbs. (7 Nm) on the 2.4L engine.
  6.  
  7. Install the accelerator cable bracket.
  8.  
  9. On the 2.4L engine, install the MAP sensor.
  10.  
  11. Install the throttle, cruise (if equipped), and transmission control (automatic transaxles only) cables.
  12.  
  13. Connect the vacuum hoses from the throttle body.
  14.  
  15. Attach the connectors for the TP sensor and IAC valve.
  16.  
  17. Install the air cleaner resonator and outlet hose.
  18.  
  19. Connect the negative battery cable.
  20.  

 
label.common.footer.alt.autozoneLogo