Saturn Coupes/Sedans/Wagons 1991-1998 Repair Guide

Throttle Body

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REMOVAL & INSTALLATION



See Figures 1 through 12

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air intake tube and resonator.
  4.  
  5. Unplug the electrical connectors from the Idle Air Control (IAC) valve and the Throttle Position Sensor (TPS).
  6.  
  7. Disconnect the vacuum harness from the top of the throttle body.
  8.  
  9. Disconnect the throttle cable.
  10.  
  11. Remove the throttle body retaining bolts, then remove the throttle body assembly from the side of the intake manifold. Block the intake manifold entry with a clean cloth to prevent dirt or debris from entering and damaging the engine.
  12.  
  13. If the same unit is going to be installed on the intake manifold, examine the throttle body bore for excessive carbon build-up. If required, use carburetor cleaner, or equivalent, and a shop towel to clean the bore. Do not allow the solvent or cleaner to contact the IAC valve or TPS; remove the sensors from the throttle body, if necessary.
  14.  

To install:
  1. Remove the old gasket and discard, then thoroughly clean the gasket mating surfaces. Clean the old Loctite® threadlock from the throttle body mounting bolt threads.
  2.  
  3. Remove the cloth from the intake manifold opening, then inspect the opening for any foreign debris or pieces of gasket material.
  4.  
  5. Position a new flange gasket, then install the throttle body assembly to the intake manifold. Apply a coat of Loctite® 242, or an equivalent threadlock, to the mounting bolts, then install and tighten to 23 ft. lbs. (31 Nm).
  6.  

If the throttle body is being replaced, the idle stop screw on the new unit is preset by the manufacturer and should not require adjustment. Minimum idle speed should ONLY be adjusted if all other engine systems are operating properly and idle speed still cannot be maintained.

  1. Connect the throttle cable to the lever, making sure the cable does not hold the lever open when the accelerator pedal is released.
  2.  
  3. Connect the vacuum harness to the top of the throttle body.
  4.  
  5. Connect the IAC valve and TPS wiring harnesses.
  6.  
  7. Install the air intake tube and resonator.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the engine and check for vacuum leaks.
  12.  



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Fig. Fig. 1: Disconnect the air hose between the camshaft cover and air cleaner inlet hose



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Fig. Fig. 2: Loosen the air inlet hose clamp at the throttle body



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Fig. Fig. 3: Disconnect the air inlet hose at the throttle body and remove it from the vehicle



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Fig. Fig. 4: Unplug the IAC and TPS wiring connectors at the throttle body



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Fig. Fig. 5: Disconnect the vacuum line harness from the top of the throttle body



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Fig. Fig. 6: Turn the throttle lever to the wide open position, then disengage the cable



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Fig. Fig. 7: Loosen the throttle body mounting bolts



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Fig. Fig. 8: Remove the throttle body unit from the intake manifold



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Fig. Fig. 9: Block the intake manifold opening with a clean rag to prevent any debris from entering



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Fig. Fig. 10: Examine the throttle body bore for excessive dirt build-up



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Fig. Fig. 11: Clean the throttle body unit with carburetor cleaner and a rag. Do not allow solvent to contact the IAC valve or TPS



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Fig. Fig. 12: Remove and discard the throttle body gasket. Be careful not to score the gasket sealing surface

BASE IDLE SPEED ADJUSTMENT



For information concerning adjustment of the base idle speed, refer to Idle Speed and Mixture Adjustments in General Information & Maintenance .

 
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