Volvo Truck 2003-05

Throttle Body

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Removal & Installation



6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    The negative battery terminal.
     
    The charge air cooler.
     
    The intake pipes between the front cover plate and air cleaner housing.
     
    The hose between the turbocharger and the charge air cooler at its upper end. Push it to one side.
     
    The pipe between the throttle body and the charge air cooler.
     

  4.  
  5. Removing the throttle body:
    1. Disconnect the throttle body connector.
    2.  
    3. Remove the mounting bolts from the throttle body.
    4.  
    5. Lift up and remove the throttle body. Discard the gasket.
    6.  

  6.  

To install:

  1. Clean the mating surfaces thoroughly.
  2.  
  3. Install the throttle body using a new gasket. Tighten the 4 bolts to 88 inch lbs. (10 Nm).
  4.  
  5. Connect the throttle body connector.
  6.  
  7. Install or connect the following:
    NOTE
    After replacing the throttle unit, the throttle unit must be adapted using the vehicle communication input: Adaptation of the electronic throttle unit. Remedy as necessary.



    The pipe between the charge air cooler and the throttle body.
     
    The hose between the charge air cooler and the turbocharger.
     
    The intake pipes between the front cover plate and the air cleaner housing.
     
    The battery negative lead.
     

  8.  

8-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    The negative battery terminal
     
    The intake hose by removing the 2 hose clips and bending aside the intake hose
     
    The connector from the electronic throttle body module
     
    The 2 coolant hoses attached to the throttle body and seal off the ends with a locking pliers
     
    The 2 nuts and the 2 bolts holding throttle body against intake manifold
     
    The throttle body

    Click image to see an enlarged view

    Fig. Location of throttle body with attached coolant hoses-8-Cylinder Engines

    Location of throttle body with attached coolant hoses-8-Cylinder Engines
     

  4.  

To install:

  1. Scrap the old gasket material to ensure a clean surface.
  2.  
  3. Install or connect the following:

    A new throttle body gasket
     
    The throttle body
     
    The 2 nuts and 2 bolts. Tighten to 88 inch lbs. (10 Nm)
     
    The 2 coolant hoses secure to throttle body with hose clips
     
    The connector to the electronic throttle body module
     
    The intake hose. Tighten the 2 hose clips.
     
    The negative battery terminal
     

  4.  

5-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    The negative battery terminal.
     
    The air intake between the front cover plate and the air cleaner housing.
     
    The charge air pipe between the charge air cooler and the electronic throttle body.
     

  4.  
  5. Remove the throttle body:
    1. Disconnect the connector for the throttle body.
    2.  
    3. Remove the 4 bolts from the throttle body.
    4.  
    5. Lift out the throttle body and discard the gasket.

      Click image to see an enlarged view

      Fig. Throttle body location-5-Cylinder Engines

      Throttle body location-5-Cylinder Engines
    6.  

  6.  

To install:


NOTE
Ensure that the surfaces between the throttle body and the intake manifold are clean.

  1. Install electronic throttle body using a new gasket. Tighten the 4 bolts to 88 inch lbs. (10 Nm).
  2.  
  3. Install the charge air pipe between the electronic throttle body module and the charge air cooler.
    NOTE
    Heat the pipe at the connections to facilitate installation.

  4.  
  5. Install the intake pipe between the front cover plate and the air cleaner housing.
  6.  
  7. Start the engine and check the function of the electronic throttle body module.
    NOTE
    After replacing the throttle unit, the throttle unit must be adapted using the vehicle communication input: Adaptation of the electronic throttle unit. Remedy as necessary.

  8.  

 
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