Tracker 2000-2004

Throttle Body

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Removal & Installation



1.6L & 2.0L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the intake air inlet duct from the throttle body.
  4.  
  5. Remove the breather hose from the throttle body.
  6.  
  7. Disconnect the Throttle Position (TP) sensor electrical connector.
  8.  
  9. Disconnect the Idle Air Control (IAC) valve electrical connector.
  10.  
  11. Drain the cooling system.
  12.  
  13. Disconnect the lower coolant hose from the throttle body.
  14.  
  15. Disconnect the upper coolant hose from the throttle body.
  16.  
  17. Disconnect the accelerator control cable from the throttle body by rotating the throttle lever to wide open throttle (WOT) and removing the cable end from the slot.
  18.  
  19. If necessary, disconnect the A/T throttle cable from the throttle body throttle lever by removing the cable end from the throttle lever slot.
  20.  
  21. Remove the two nuts and/or two bolts (1) from the throttle body.
  22.  
  23. Remove the throttle body and gasket from the intake manifold.
  24.  
  25. Clean any throttle body gasket that remains on the intake manifold.

    Click image to see an enlarged view

    Fig. Throttle body mounting nuts/bolts (1), throttle body (2), gasket (3), and intake manifold (4)-1.6L and 2.0L engines

  26.  

To install:

  1. Install a new gasket and the throttle body onto the intake manifold.
  2.  
  3. Secure the throttle body to the intake manifold with the two nuts and/or two bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  4.  
  5. If necessary, connect the A/T throttle cable to the throttle lever and adjust as necessary.
  6.  
  7. Connect the accelerator control cable to the throttle lever. Adjust the accelerator control cable as necessary.
  8.  
  9. Connect the lower coolant hose to the throttle body.
  10.  
  11. Connect the upper coolant hose to the throttle body.
  12.  
  13. Connect the IAC valve electrical connector.
  14.  
  15. Connect the TP sensor electrical connector.
  16.  
  17. Connect the breather hose to the throttle body.
  18.  
  19. Install the intake air inlet duct to the throttle body.
  20.  
  21. Connect the negative battery cable.
  22.  

2.5L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the front suspension support brace.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove the four fasteners and the engine surge tank cover.
  8.  
  9. Remove the four nuts retaining the intake surge tank.
  10.  
  11. Remove the two air inlet duct fasteners and remove the engine surge tank.
  12.  
  13. Loosen the hose clamps and remove the intake air inlet duct from the throttle body.
  14.  
  15. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
  16.  
  17. Disconnect the Throttle Position (TP) sensor electrical connector.
  18.  
  19. Disconnect the two coolant hoses from the throttle body.
  20.  
  21. Disconnect Idle Air Control (IAC) air hose from the top of the throttle body.
  22.  
  23. Disconnect the accelerator control cable from the throttle body. Rotate the throttle lever to wide open throttle (WOT) and remove the cable end from the slot.
  24.  
  25. Remove the two fasteners and the accelerator cable bracket from the throttle body.
  26.  
  27. Extend the transmission throttle valve cable and disconnect the cable end from the throttle lever.
  28.  
  29. Remove the two bolts and the four nuts attaching the intake collector to the intake manifold.
  30.  
  31. Remove the two bolts and the two nuts attaching the throttle body to the intake collector.
  32.  
  33. Remove the breather hose from the throttle body.
  34.  
  35. Move the throttle body towards the front, while sliding the intake collector towards the rear, in order to remove the throttle body from the vehicle.

    Click image to see an enlarged view

    Fig. Throttle body and intake collector assembly-2.5L engine

  36.  

To install:

  1. Install a new throttle body gasket onto the intake collector.
  2.  
  3. Connect the breather hose to the throttle body.
  4.  
  5. Install the throttle body onto the intake collector.
  6.  
  7. Slide the intake collector forward and attach to the intake manifold.
  8.  
  9. Secure the intake collector to the intake manifold with the 2 bolts and 4 nuts. Tighten the fasteners to 16 ft. lbs. (23 Nm).
  10.  
  11. Secure the throttle body to the intake collector with the 2 nuts and 2 bolts. Tighten the fasteners to 8.5 ft. lbs. (12 Nm).
  12.  
  13. Connect the accelerator control cable to the throttle body. Rotate the throttle lever to WOT and insert the cable end into the slot.
  14.  
  15. Connect the transmission throttle valve cable to the throttle lever.
  16.  
  17. Adjust the transmission throttle valve cable as necessary.
  18.  
  19. Adjust the accelerator control cable as necessary.
  20.  
  21. Connect the two coolant hoses to the throttle body.
  22.  
  23. Connect the IAC air hose to the throttle body.
  24.  
  25. Connect the TP sensor electrical connector.
  26.  
  27. Connect the MAF sensor electrical connector.
  28.  
  29. Connect the intake air inlet duct to the throttle body.
  30.  
  31. Secure the inlet duct with the hose clamp.
  32.  
  33. Connect the intake surge tank to the intake manifold.
  34.  
  35. Secure the intake surge tank with four nuts and tighten them to 16 ft. lbs. (23 Nm).
  36.  
  37. Install the engine surge tank cover and secure with the four fasteners.
  38.  
  39. Install the front suspension brace.
  40.  
  41. Refill the engine coolant.
  42.  
  43. Connect the negative battery cable.
  44.  

 
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