Malibu 2001-2005

Throttle Body

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Removal & Installation



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 throttle body harness connector.
  4.  
  5. Remove the throttle body attaching bolts.
  6.  
  7. Remove the throttle body from the intake manifold.

    Click image to see an enlarged view

    Fig. The removal and installation of the throttle body

  8.  

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 lb inches (10 Nm).
  6.  
  7. Connect the throttle body harness connector.
  8.  
  9. Install the air cleaner resonator.
  10.  

  1. Before servicing the vehicle, refer to the Precautions Section.
    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 Peroxide (MEKP). This solvent may damage fuel system components.

  2.  
  3. Remove the air cleaner resonator.
  4.  
  5. Disconnect the throttle body harness connector.
  6.  
  7. Remove the throttle body attaching bolts.
  8.  
  9. Remove the throttle body from the intake manifold.

    Click image to see an enlarged view

    Fig. The removal and installation of the throttle body

  10.  

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 lb inches (10 Nm).
  6.  
  7. Connect the throttle body harness connector.
  8.  
  9. Install the air cleaner resonator.
  10.  

3.1L Engine
  1. Turn OFF the ignition.
  2.  
  3. Drain enough of the engine coolant to prevent leakage from the throttle body coolant bypass hoses.

    Click image to see an enlarged view

    Fig. Disconnect the breather tube from the air intake tube

  4.  
  5. Disconnect the breather tube from the air intake tube.
  6.  
  7. Remove the air intake tube.
  8.  
  9. Disconnect the idle Air Control (IAC) valve electrical connector.

    Click image to see an enlarged view

    Fig. Disconnect the Throttle Position (TP) sensor electrical connector

  10.  
  11. Disconnect the Throttle Position (TP) sensor electrical connector.
  12.  
  13. Disconnect the accelerator controls cable.
  14.  
  15. If applicable disconnect the cruise control cable from the throttle lever and accelerator bracket.

    Click image to see an enlarged view

    Fig. Remove the accelerator control cable bracket

  16.  
  17. Remove the accelerator control cable bracket.
  18.  
  19. Unsnap the wire harness clip from bracket.
  20.  
  21. Disconnect the throttle body coolant bypass hoses.
  22.  
  23. Disconnect the heater pipe nut at the throttle body.
  24.  
  25. Remove the nuts and bolts holding the throttle body to the intake manifold.

    Click image to see an enlarged view

    Fig. Remove the throttle body assembly

  26.  
  27. Remove the throttle body assembly.
  28.  

To install:


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.

  1. Clean the gasket surface on the intake manifold and the throttle body assembly.
  2.  
  3. Install a new gasket, if necessary.
  4.  
  5. Install the throttle body assembly.
    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.

  6.  
  7. Install the throttle body retaining nuts and bolts, and tighten the throttle body retaining nuts and bolts to 21 ft. lbs. (28 Nm).
  8.  
  9. Connect the throttle body coolant bypass hoses.
  10.  
  11. Connect the heater pipe nut at the throttle body.
  12.  
  13. Connect the IAC valve electrical connector.
  14.  
  15. Connect the TP sensor electrical connector.
  16.  
  17. Install the accelerator controls cable bracket.
  18.  
  19. Install the wire harness clip.
  20.  
  21. If applicable connect the cruise control cable to the throttle lever and accelerator bracket.
  22.  
  23. Connect the accelerator controls cable.
  24.  
  25. Install the air intake tube.
  26.  
  27. Connect the air intake tube.
  28.  
  29. Connect the IAT sensor electrical connector.
  30.  
  31. Connect the breather into the air tube.
  32.  
  33. Fill the coolant.
    NOTE
    The throttle should operate freely without binding between full closed and wide open throttle.

  34.  
  35. Inspect for complete throttle opening and closing positions by operating the accelerator pedal. Also check for poor carpet fit under the accelerator pedal.
  36.  

3.5L Engine
  1. Remove the air cleaner intake duct.
  2.  
  3. Disconnect the Electronic Throttle Control (ETC) electrical connector.

    Click image to see an enlarged view

    Fig. Remove the heater pipe nut at the throttle body

  4.  
  5. Remove the heater pipe nut at the throttle body.
  6.  
  7. Remove the nuts and the bolts from the throttle body.

    Click image to see an enlarged view

    Fig. Remove the throttle body assembly

  8.  
  9. Remove the throttle body assembly.
  10.  
  11. Remove the throttle body gasket.
    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.

  12.  
  13. Clean and inspect the throttle body gasket mating surfaces.
  14.  

To install:

  1. Install a new gasket, if necessary.
  2.  
  3. Install the throttle body assembly.
  4.  
  5. Install the throttle body nuts and the bolts, and tighten the nuts and the bolts to 89 lb inches (10 Nm).
  6.  
  7. Install the heater pipe nut to the throttle body, and tighten the nut to 18 ft. lbs. (25 Nm).
  8.  
  9. Connect the ETC electrical connector.
  10.  
  11. Install the air cleaner intake duct.
  12.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the air cleaner intake duct.
  4.  
  5. Disconnect the Electronic Throttle Control (ETC) electrical connector.

    Click image to see an enlarged view

    Fig. Remove the heater pipe nut at the throttle body

  6.  
  7. Remove the heater pipe nut at the throttle body.
  8.  
  9. Remove the nuts and the bolts from the throttle body.

    Click image to see an enlarged view

    Fig. Remove the throttle body assembly

  10.  
  11. Remove the throttle body assembly.
  12.  
  13. Remove the throttle body gasket.
    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.

  14.  
  15. Clean and inspect the throttle body gasket mating surfaces.
  16.  

To install:

  1. Install a new gasket, if necessary.
  2.  
  3. Install the throttle body assembly.
  4.  
  5. Install the throttle body nuts and the bolts, and tighten the nuts and the bolts to 89 lb inches (10 Nm).
  6.  
  7. Install the heater pipe nut to the throttle body, and tighten the nut to 18 ft. lbs. (25 Nm).
  8.  
  9. Connect the ETC electrical connector.
  10.  
  11. Install the air cleaner intake duct.
  12.  

3.9L 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.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the intake manifold cover.
  4.  
  5. Remove the air cleaner outlet duct.
  6.  
  7. Disconnect the Electronic Throttle Control (ETC) electrical connector.
  8.  
  9. Remove the heater inlet and outlet pipe nuts.
  10.  
  11. Remove the heater inlet and outlet pipe bracket from the throttle body studs. Reposition the pipes.
  12.  
  13. Remove the throttle body bolts/studs.
  14.  
  15. Remove the throttle body.
  16.  
  17. Remove the throttle body gasket.
  18.  

To install:

  1. Install a new gasket, if necessary.
  2.  
  3. Install the throttle body.
  4.  
  5. Install the throttle body bolts and studs tighten to 89 inch. lbs. (10 Nm).
  6.  
  7. Position the heater inlet and outlet pipes and install the pipe bracket to the throttle body studs.
  8.  
  9. Install the heater inlet and outlet pipe nuts and tighten to 89 inch. lbs. (10 Nm).
  10.  
  11. Connect the ETC electrical connector.
  12.  
  13. Install the air cleaner outlet duct.
  14.  
  15. Install the intake manifold cover.
  16.  

 
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