Throttle Body: Service and Repair

To Remove
1. Remove the engine covers.
2. Remove the rubber hose section. Remove the cable conduits and the intake manifold's mounting bracket.
3. Disconnect the throttle and cruise control cables from the throttle lever and bracket. Detach the brake servo and crankcase ventilation vacuum hoses.
4. Remove the 7 nuts securing the upper half of the intake manifold.
5. Lift up the upper half of the intake manifold and support it with a rubber mallet or the like.

IMPORTANT: Plug the intake pipes with paper or rags to prevent screws and the like from falling into the cylinders.





6. Remove the 4 nuts retaining the main throttle and TCS throttle.
Withdraw the main throttle and disconnect the hoses.





To Install
1. Position a new outer gasket on the TCS throttle. Make sure that the holes coincide.
2. Install the throttle body in place and tighten the four retaining nuts.

Tightening torque: 8 Nm (6 ft lbs).

3. Connect all hoses to the throttle body.
4. If necessary, clean the intake manifold mating surfaces. Remove the paper or rags plugging the intake pipes and install a new gasket.
Correctly position the upper half of the intake manifold.





5. Tighten all the intake manifold retaining nuts. Start by tightening the nuts in the middle and continue alternately to the outermost nuts.

Tightening torque: 20 Nm (15 ft lbs).

6. Tighten the mounting bracket at the rear of the intake manifold.
7. Install the cable conduits.
8. Check that the pressure regulator's vacuum hose is fitted on the throttle body's front connector (in front of the throttle valve).
9. Reconnect the crankcase ventilation and brake servo vacuum hoses and install the throttle and cruise control cables to the throttle lever and mounting bracket.
10. Install the rubber hose section and tighten the hose clips. Reconnect the IAC hose.
11. Install the covers on the engine.