REMOVAL & INSTALLATION
Navajo and B Series Pick-up Models
See Figures 1 through 10
The 3.0L engine's throttle body is a 1 piece casting which includes the upper intake manifold. In order to remove the throttle body, the entire upper manifold must be removed. Refer to Engine & Engine Overhaul for the proper procedures.
- Loosen the air inlet tube clamps, then separate the tube from the throttle body and air cleaner housing. Remove the tube from the vehicle.
- If equipped, remove the throttle linkage shield.
- Detach the accelerator and speed control (if equipped) cables from the throttle body lever.
- Label and disengage the engine wiring harness connectors from the Throttle Position (TP) sensor and the Idle Air Control (IAC) valve; both are mounted on the throttle body.
- Remove the four mounting nuts, then carefully separate the throttle body from the upper intake manifold.
- Remove and discard the old throttle body-to-intake manifold gasket.
If scraping is necessary to clean the remaining gasket material off of the mating surfaces, take care to avoid scratching or gouging the soft aluminum.
- Clean the gasket mating surfaces of any residual gasket material.
- Install the throttle body, along with a new gasket, onto the upper intake manifold. Install and tighten the mounting nuts in a crisscross pattern to specifications.
- Engage the TP sensor and IAC valve wiring connectors and remove the temporary labels.
- Reattach the accelerator and speed control cables, if applicable, to the throttle body lever.
- If removed, install the throttle linkage shield.
- Install the air inlet tube between the air cleaner housing and the throttle body. Tighten the tube clamps until snug.
See Figures 11 and 12
- Disconnect the battery ground.
- Disconnect the air hose.
- Disconnect the ventilation hose.
- Remove the air pipe and resonance chamber.
- Disconnect the accelerator cable from the throttle lever.
- Drain the engine coolant.
- Disconnect the coolant lines at the manifold.
- Tag and disconnect all vacuum hoses.
- Tag and disconnect all wiring.
- Unbolt and remove the throttle body.
- Always use a new mounting gasket. Place the new gasket and throttle body in position. Install and torque the fasteners to 14-18 ft. lbs. (19-25 Nm). Connect the vacuum lines, hoses and intake system components. Fill the cooling system.
See Figures 13 and 14
- Disconnect battery negative cable.
- Drain approximately 2 qts. of coolant from the engine.
- Loosen air cleaner-to-throttle body hose clamps and remove hose.
- Remove accelerator cable.
- Remove harness connector from throttle position sensor (TPS).
- Disconnect the water hoses.
- Label and remove vacuum hoses necessary.
- Remove throttle body mounting nuts and remove throttle body and gasket.
- Install throttle body using a new gasket on air intake plenum. Secure with mounting nuts. Tighten the mounting nuts to 14-18 ft. lbs. (19-25 Nm).
- Reconnect water hoses and TPS connector.
- Reconnect accelerator cable.
- Install air cleaner to throttle body hose and tighten clamps.
- Add the necessary amount of engine coolant.
- Reconnect battery negative cable. Adjust the idle speed, if necessary.
See Figure 15
- Disconnect the negative battery cable.
- Remove the clamps and remove the air intake hose from the throttle body and the MAF sensor.
- Disconnect the accelerator cable and if equipped, the cruise control cable.
- Disconnect the throttle position sensor connector.
- Remove the 2 bolts and the 2 nuts and remove the throttle body unit and gasket.
- Using a new gasket, install the throttle body assembly with the 2 bolts and the 2 nuts. Torque the bolts and nuts to 14-18 ft. lbs. (19-25 Nm).
- Reconnect the throttle position sensor connector.
- Reconnect the accelerator cable and if equipped, the cruise control cable.
- Install the air intake hose to the throttle body assembly and the MAF sensor with the 2 clamps.
- Connect the negative battery cable, start the engine and operate until normal temperature, check for proper operation.