HHR 2006-2008

Throttle Body

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Removal & Installation



2.0L Engine

WARNING
Do not use solvent 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. Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the charge air cooler outlet pipe.
  4.  
  5. Disconnect the engine wiring harness electrical connector from the Electronic Throttle Control (ETC).
  6.  
  7. Disconnect the engine wiring harness electrical connector from the brake booster auxiliary pump.
  8.  
  9. Remove the brake booster auxiliary pump electrical connector clip from the bracket.
  10.  
  11. Remove the throttle body bolts.
  12.  
  13. Remove the throttle body and seal from the intake manifold.

    Click image to see an enlarged view

    Fig. Throttle body-2.0L engine

  14.  

To install:

  1. Inspect the throttle body seal, and replace if necessary.
  2.  
  3. Position the throttle body to the intake manifold.
  4.  
  5. Install the throttle body bolts and tighten to 89 inch lbs. (10 Nm).
  6.  
  7. Connect the engine wiring harness electrical connector to the brake booster auxiliary pump.
  8.  
  9. Install the brake booster auxiliary pump electrical connector clip to the bracket.
  10.  
  11. Connect the engine wiring harness electrical connector to the ETC.
  12.  
  13. Install the charge air cooler outlet pipe.
  14.  

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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