PT Cruiser, 2001 - 2005

Throttle Body

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Removal & Installation



Except Turbocharged Models
  1. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose.
  2.  
  3. Remove the negative battery cable.
  4.  
  5. Remove the engine cover or throttle control shield if equipped.
  6.  
  7. Remove throttle cable from the throttle body cam.
  8.  
  9. Lift the retaining tabs on the cable and slide cable out of bracket.
  10.  
  11. If equipped with speed control, remove speed control cable from throttle lever by sliding clasp out hole used for throttle cable.
  12.  
  13. Remove EVAP purge hose from nipple on throttle body.
  14.  
  15. Remove the electrical connectors from the throttle position sensor and idle air control motor.
  16.  
  17. Remove 2 screws holding cable mounting bracket and support bracket.
  18.  
  19. Remove throttle body mounting bolts.
  20.  
  21. Lift throttle body straight up and away to remove the throttle body.
  22.  

To install:

Click image to see an enlarged view

Fig. Installation of the throttle body-2.4L non-turbo engine

  1. Attach electrical connectors to idle air control motor and throttle position sensor.
  2.  
  3. Make sure that the throttle body gasket is in place in the manifold.
  4.  
  5. Position throttle body on intake and install mounting bolts. Do Not tighten bolts at this time.
  6.  
  7. Install throttle cable bracket. Do Not tighten bolts at this time.
  8.  
  9. Tighten throttle body bolts to 85-125 inch lbs. (9.55-14.05Nm).
  10.  
  11. Tighten throttle cable bracket bolts to 85-125 inch lbs. (9.55-14.05Nm).
  12.  
  13. Install EVAP purge hose to throttle body nipple.
  14.  
  15. Install cable housing(s) retainer tabs into bracket.
  16.  
  17. Install throttle body cables by rotating the throttle cam forward to the wide open position.
  18.  
  19. Install throttle control shield.
  20.  
  21. Install the negative battery cable.
  22.  
  23. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose.
  24.  

Turbocharged Models
  1. Disconnect the negative battery cable.
  2.  
  3. Unlock and disconnect the electrical connector for the inlet air temperature sensor.
  4.  
  5. Unlock and disconnect the electrical connectors from the idle air control motor and throttle position sensor.
  6.  
  7. Remove the throttle control shield.
  8.  
  9. Remove the throttle cable from the throttle body cam.
  10.  
  11. If equipped with speed control, remove speed control cable from the throttle cam by sliding clasp out hole used for throttle cable.
  12.  
  13. Remove the 2 screws for the throttle cable bracket.
  14.  
  15. Remove bracket.
  16.  
  17. Disconnect the throttle body inlet hose and remove from throttle body.
  18.  
  19. Disconnect the purge hose from the throttle body.
  20.  
  21. Remove the 3 bolts from the throttle body.
  22.  
  23. Remove the throttle body.
  24.  
  25. Clean and replace gasket.
  26.  

To install:

Click image to see an enlarged view

Fig. Installation of the throttle body-2.4L turbo engine

  1. Discard old gasket and clean intake manifold surface.
  2.  
  3. Install the throttle body.
  4.  
  5. Install the 3 bolts to the throttle body and tighten to 85-125 inch lbs. (9.55-14.05Nm).
  6.  
  7. Connect the purge hose to the throttle body.
  8.  
  9. Connect the throttle body inlet hose to the throttle body and tighten clamp.
  10.  
  11. Install bracket.
  12.  
  13. Install the 2 screws for the throttle cable bracket and tighten to 85-125 inch lbs. (9.55-14.05Nm).
  14.  
  15. If equipped with speed control, install speed control cable to the throttle cam by sliding clasp in the hole used for throttle cable.
  16.  
  17. Install the throttle cable to the throttle body cam.
  18.  
  19. Install the throttle control shield.
  20.  
  21. Connect and lock the electrical connectors from the idle air control motor and throttle position sensor.
  22.  
  23. Connect and lock the electrical connector for the inlet air temperature sensor.
  24.  
  25. Connect the negative battery cable.
  26.  

 
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