ION, L-Series, S-Series 1999-2005

Throttle Body

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The throttle body injection unit is made up of 2 major casting assemblies. The top piece, or fuel meter body, contains the fuel injector and pressure regulator. The bottom piece, or throttle body, contains the throttle valve, IAC valve, TPS, and the vacuum manifold or tubes which supply manifold vacuum to various engine control solenoids.

Click image to see an enlarged view

Fig. Exploded view of the throttle body injection unit

Removal & Installation



2.0L Engine

NOTE
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.


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

  1. Remove the air cleaner outlet duct.
  2.  
  3. Disconnect the evaporative emission (EVAP) purge line.
  4.  
  5. Disconnect the throttle body control harness connector.
  6.  
  7. Remove the throttle body attaching bolts .
  8.  
  9. Remove the throttle body and gasket from the supercharger.
  10.  

To install:

Click image to see an enlarged view

Fig. The removal and installation of the throttle body

  1. Inspect the throttle body gasket and replace if necessary.
  2.  
  3. Install the throttle body to the supercharger.
  4.  
  5. Install the throttle body attaching bolts, and tighten the throttle body attaching bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Connect the throttle body control harness connector .
  8.  
  9. Connect the EVAP purge line.
  10.  
  11. Install the air cleaner outlet duct.
  12.  

2.2L Engine

NOTE
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.


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

  1. Remove the air cleaner resonator.
  2.  
  3. Disconnect the Idle Air Control (IAC) valve harness connector.
  4.  
  5. Disconnect the Throttle Position (TP) sensor harness connector.

    Click image to see an enlarged view

    Fig. Disconnect the Idle Air Control (IAC) and the Throttle Position (TP) sensor harness connectors

  6.  
  7. Disconnect the vacuum hoses at the throttle body.

    Click image to see an enlarged view

    Fig. Remove the bolts (1) and throttle body (4) from the intake manifold

  8.  
  9. Remove the throttle body attaching bolts.
  10.  
  11. Remove the throttle body from the intake manifold.
  12.  

To install:

  1. Inspect the throttle body gasket and replace if necessary.
  2.  
  3. Install the throttle body to the intake manifold.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4.  
  5. Install the throttle body attaching bolts, and tighten the throttle body attaching bolts to 89 inch lbs.(10 Nm).
  6.  
  7. Connect the vacuum hoses to the throttle body.
  8.  
  9. Connect the TP sensor harness connector.
  10.  
  11. Connect the IAC valve harness connector.
  12.  
  13. Install the air cleaner resonator.
  14.  
  15. Test the accelerator movement by depressing the pedal to the floor and releasing the pedal.
  16.  


NOTE
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.


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

  1. Remove the air cleaner resonator.
  2.  
  3. Disconnect the Idle Air Control (IAC) valve harness connector.
  4.  
  5. Disconnect the Throttle Position (TP) sensor harness connector.

    Click image to see an enlarged view

    Fig. Disconnect the Idle Air Control (IAC) and the Throttle Position (TP) sensor harness connectors

  6.  
  7. Disconnect the vacuum hoses at the throttle body.

    Click image to see an enlarged view

    Fig. Remove the bolts (1) and throttle body (4) from the intake manifold

  8.  
  9. Remove the throttle body attaching bolts.
  10.  
  11. Remove the throttle body from the intake manifold.
  12.  

To install:

  1. Inspect the throttle body gasket and replace if necessary.
  2.  
  3. Install the throttle body to the intake manifold.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4.  
  5. Install the throttle body attaching bolts, and tighten the throttle body attaching bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Connect the vacuum hoses to the throttle body.
  8.  
  9. Connect the TP sensor harness connector.
  10.  
  11. Connect the IAC valve harness connector.
  12.  
  13. Install the air cleaner resonator.
  14.  
  15. Test the accelerator movement by depressing the pedal to the floor and releasing the pedal.
  16.  

2.4L Engine
  1. Remove the air cleaner outlet duct.
  2.  
  3. Remove the intake manifold cover.
  4.  
  5. Disconnect the Throttle Actuator Control (TAC) electrical connector.
  6.  
  7. Remove the throttle body bolts.
  8.  
  9. Remove the throttle body .
  10.  
  11. Inspect the throttle body gasket, and replace if necessary.
  12.  

To install:

  1. Install the throttle body. Tighten the bolts to 89 inch lbs. (10 Nm).
  2.  
  3. Connect the TAC electrical connector.
  4.  
  5. Install the intake manifold cover.
  6.  
  7. Install the air cleaner outlet duct.
  8.  

Throttle Body Relearn Procedure



  1. Turn the ignition OFF for 10 seconds
  2.  
  3. Turn the Ignition ON with the engine OFF
  4.  
  5. Make sure these engine operating parameters are met before proceeding
  6.  
  7. The ECT is between 43 to 212°F (6 to 100°C).
  8.  
  9. The IAT is greater than 43°F (6°C).
  10.  
  11. The ignition voltage is above 10 volts.
  12.  
  13. The accelerator pedal angle is less than 14 percent.
  14.  
  15. Leave the ignition ON for 1 minute with the engine OFF
  16.  

  1. Turn the ignition OFF for 10 seconds
  2.  
  3. Turn the Ignition ON with the engine OFF
  4.  
  5. Make sure these engine operating parameters are met before proceeding
  6.  
  7. The ECT is between 43 to 212°F (6 to 100°C).
  8.  
  9. The IAT is greater than 43°F (6°C).
  10.  
  11. The ignition voltage is above 10 volts.
  12.  
  13. The accelerator pedal angle is less than 14 percent.
  14.  
  15. Leave the ignition ON for 1 minute with the engine OFF
  16.  

 
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