Throttle Body Assembly Removal and Replacement
Throttle Body Assembly Replacement.:
Throttle Body Exploded View.:
WARNING: Do not allow smoking or the use of open flames in the area where work on the fuel system is taking place. Anytime the fuel system is being worked on, disconnect the negative battery cable, except for those tests where battery voltage is required.
WARNING: Whenever fuel line fittings are loosened or disconnected, wrap a shop cloth around fitting while connecting gauge, to collect fuel. Place cloth in an approved container.
THROTTLE BODY INJECTION (TBI) UNIT REMOVAL
1. Disconnect negative battery terminal.
2. Remove the TBI air cleaner assembly.
3. Connect fuel gage bar kit SA9127E (or equivalent) to fuel pressure test port.
4. Install bleed hose into an approved container and open valve to bleed system pressure. After system pressure is bled, remove gauge from fuel pressure test port and recap it.
5. Disconnect the following electrical connectors:
a. Idle air control (IAC)
b. Throttle position sensor (TPS)
c. Fuel injector
6. Remove grommet with wires from throttle body.
7. Disconnect throttle cable from the throttle body lever.
8. Disconnect vacuum lines, noting positions of lines.
NOTE: Label vacuum hoses to insure they are replaced properly.
9. Remove supply and return fuel line nuts, using backup wrench.
10. Remove fuel line O-rings from nuts and discard.
11. Remove TBI unit attachment bolts.
NOTE: Block the intake manifold opening with a clean shop towel to prevent dirt or debris from entering.
12. Remove TBI unit from intake manifold.
13. Remove TBI flange (manifold) gasket and discard.
14. Remove any old gasket material from the intake manifold and clean Loctite sealant material from bolt threads.
INSTALLATION
1. Inspect manifold opening for debris. Remove any loose parts and/or foreign material.
2. Inspect intake manifold sealing surface for scores and cleanliness.
3. Install new TBI flange (manifold) gasket.
4. Install TBI unit on intake manifold.
5. Apply SATURN P/N 21485277 (Loctite 242 or equivalent) to the attachment bolt threads. Install TBI unit attachment bolts.
^ Torque: 33 Nm (24 ft lbs)
6. If removed, install fuel meter body attaching screws.
7. Torque fuel meter body attaching screws even if they were not removed.
^ Torque: 4 Nm (35 in lbs)
8. Install new O-rings in fuel inlet and return nuts.
^ Torque: 25 Nm (19 ft lbs)
9. Install fuel line inlet and outlet nuts, using backup wrench.
^ Torque: 25 Nm (19 ft lbs)
WARNING: If fuel lines were disconnected at connectors, lubricate steel line male ends with clean engine oil. Holding steel line, firmly press on female coupler until a click is heard, then pull back to confirm engagement. Pinched, kinked or damaged fuel lines must be replaced.
10. Connect throttle cable to throttle body.
11. Connect the following electrical connectors and vacuum hoses:
a. Electrical connectors:
^ Throttle position sensor (TPS)
^ Idle air control (IAC)
^ Fuel Injector
NOTE: Push in until a click is heard and pull back on connector to confirm positive engagement.
b. Vacuum Hoses:
^ EGR solenoid
^ Cannister purge solenoid
^ MAP sensor
NOTE: Make sure that hoses are firmly seated. Check for vacuum leaks upon assembly.
12. Check accelerator pedal to be certain that it is free. Depress pedal to floor and release while engine is "OFF".
13. Connect negative battery terminal.
14. Prime fuel system.
a. Cycle ignition "ON" for 5 seconds and then "OFF" for 10 seconds.
b. Repeat step 14a twice.
c. Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
d. If engine does not start, repeat steps 14a - 14c.
15. With engine "OFF" and ignition "ON", check for leaks around fuel line connections.
16. Inspect air cleaner gasket, and replace if torn, deteriorated, or damaged. Install air cleaner assembly. Attach air inlet and fresh air tubes.
17. Start engine and check for fuel leaks.