REMOVAL & INSTALLATION

CAUTION
Gasoline in either liquid or vapor state is EXTREMELY explosive. Take great care to contain spillage. Work in an open or well-ventilated area. Do not connect or disconnect electrical connectors while fuel hoses are removed or loosened. Observe smoking/no open flame rules during repairs. Have a dry-chemical fire extinguisher (type B-C) within arm's reach at all times and know how to use it.

NOTE: The throttle body for each of the MFI engines is slightly different. The procedure below is general and may require slight alteration of sequence depending on the engine.

1. Disconnect the negative battery cable.
2. Drain the coolant, at least to a level below the intake manifold.

   CAUTION
   When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

3. Disconnect the main air intake duct from the throttle body.
4. Label and disconnect the vacuum and breather hoses running to the throttle body. Take care that clamps are not bent or distorted during removal.
5. Disconnect the accelerator cable and the cruise control cable if so equipped.
6. Label and disconnect the coolant hoses running to the throttle body.
7. Follow each wire running from the throttle body. Label and disconnect each at its connector. Most of the wiring harnesses have connectors at some distance from the throttle body. Loosen, release or remove any clips or brackets holding the throttle body harnesses in place.
8. Carefully remove the four nuts and bolts holding the throttle body to the manifold. The throttle body may use bolts of two different lengths; take careful note of each bolt's position.
9. Lift the throttle body away from the manifold and handle it carefully. Place it in a protected location.
10. If the unit is being replaced, compare the old and the new ones. Look for any components which need to be transferred from the old unit. The throttle plate area may be cleaned with a spray cleaner, but must be completely dry before installation. Disassembly of the throttle body is not recommended.
11. Before reinstalling, make sure that all remains of the old gasket are removed from both the manifold flange and the base of the throttle body. Place a new gasket on the manifold and hold the throttle body in place. Don't forget the support bracket on the twin cam engines.
12. Install the four nuts and bolts finger tight. Make certain the bolts are in the correct holes by length. Tighten the bolts evenly, alternating from bolt to bolt, in small increments. The bolts must draw down evenly, creating an airtight seal against the gasket.
13. For all engines, tighten the nuts and bolts to the following torque figures. Do NOT overtighten these bolts. The figures are:
    • 1990–91 2.4L Engines — 11–16 ft. lbs. (15–22 Nm)
    • 1992 2.4L Engines — 9 ft. lbs. (12 Nm)
    • 1993–95 2.4L Engines — 14 ft. lbs. (19 Nm)
    • 1989–91 3.0L Engines — 7–9 ft. lbs. (10–13 Nm)
    • 1992–95 3.0L Engines — 10 ft. lbs. (14 Nm)
    • 1994–95 3.5L DOHC Engines — 8 ft. lbs. (12 Nm)
14. Reconnect the wiring connectors to the harnesses. Secure, tighten or reinstall any wire clips or retainers. The harnesses must be kept clear of moving or hot surfaces.

    Fig. 1: Orientation of the throttle body to the intake manifold plenum — 2.4L engines

    Fig. 2: Orientation of the throttle body to the intake manifold plenum — 3.0L engines

15. Install the coolant hoses, making sure each is properly clamped to its port.
16. Install the accelerator cable and cruise control cable if so equipped. Adjust the cable to the correct tension and make certain the lock nuts or bracket bolts are secure.
17. Connect the vacuum hoses. Examine the end of each and replace any showing signs of cracking or hardening.
18. Install the main air duct and connect the breather tubes.
19. Refill the coolant to the proper level.
20. Connect the negative battery cable.