GM Malibu/Cutlass 1997-2000

Throttle Body

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REMOVAL & INSTALLATION



2.4L Engine


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Fig. 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 from the TP sensor and IAC valve.
  6.  
  7. Tag and disconnect the vacuum hoses from the throttle body.
  8.  
  9. Remove the throttle, cruise (if equipped), and transaxle control cables from the throttle body.
  10.  
  11. Remove the MAP sensor.
  12.  
  13. Remove the accelerator cable bracket.
  14.  
  15. Unfasten the throttle body attaching bolts, then remove the throttle body from the intake manifold.
  16.  

To install:

  1. Thoroughly clean the throttle body and intake manifold mounting surfaces.
  2.  
  3. Position the throttle body onto the intake manifold.
  4.  
  5. Install the throttle body retaining bolts, and tighten to 58 inch lbs. (7 Nm).
  6.  
  7. Install the accelerator cable bracket.
  8.  
  9. Install the MAP sensor.
  10.  
  11. Attach the throttle, cruise (if equipped), and transaxle control cables.
  12.  
  13. Connect the vacuum hoses to the throttle body.
  14.  
  15. Attach the connectors to the TP sensor and IAC valve.
  16.  
  17. Install the air cleaner resonator and outlet hose.
  18.  
  19. Connect the negative battery cable.
  20.  

3.1L Engine
  1. Drain and recycle the engine coolant in a suitable container.
  2.  
  3. Remove the air intake duct.
  4.  



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Fig. Loosen the clamps at the throttle body and remove the air intake duct . . .



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Fig. . . . remove the accelerator cable control bracket to access the throttle control . . .



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Fig. . . . then, remove the accelerator control and cruise control cable ends from the throttle control by holding the throttle fully open and removing the cable end from the slotted hole



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Fig. Remove the accelerator control cable bracket and cables as an assembly

  1. Detach the IAC valve and TP sensor electrical connectors.
  2.  
  3. Remove the accelerator control cable bracket.
  4.  
  5. Remove the accelerator control and cruise control cable ends from the throttle control by holding the throttle control fully open and removing the cable end from the slotted hole. See accompanying photo for details.
  6.  
  7. Disconnect the throttle body coolant bypass hoses.
  8.  
  9. Remove the heater pipe nut from the throttle body.
  10.  
  11. Remove the nuts and bolts holding the throttle body to the intake manifold, then remove the throttle body assembly.
  12.  



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Fig. Exploded view of the throttle body and gasket-3.1L engine

  1. Clean the gasket surface on the intake manifold and the throttle body assembly.
  2.  

To install:

  1. Install a new gasket, if necessary, then position the throttle body assembly.
  2.  
  3. Install the nuts and bolts holding the throttle body to the intake manifold and hand-tighten.
  4.  
  5. Tighten the throttle body retaining nuts and bolts to 21 ft. lbs. (28 Nm).
  6.  
  7. Install the heater pipe nut at the throttle body.
  8.  
  9. Connect the throttle body coolant bypass hoses.
  10.  
  11. Hold the throttle control fully open and attach the cable ends through the slotted hole. See accompanying photo for details.
  12.  
  13. Fasten the accelerator control cable bracket to the throttle body.
  14.  
  15. Attach the IAC valve and TP sensor electrical connectors.
  16.  
  17. Install the air intake duct.
  18.  
  19. Inspect the throttle operation by operating from the accelerator pedal. Check for complete opening and closing of the throttle plate.
  20.  


NOTE
The throttle should operate freely without any binding between full closed and wide open throttle.

  1. Fill and check the engine coolant.
  2.  

 
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