GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2006 🢒 Aveo 🢒 Engine 🢒 Engine Controls - 1.6L (L91) 🢒 Throttle Body Assembly Replacement

Removal Procedure

    Caution: Refer to Battery Disconnect Caution in the Preface section.


    Object Number: 1241566 Size: SH
  1. Disconnect the negative battery cable.
  2. Remove the air intake tube from the throttle body.
  3. Disconnect the throttle cables by opening the throttle and moving the cable through the release slot.

    4. Object Number: 1241930 Size: SH
  4. Disconnect the vacuum hoses from the throttle body.
  5. Disconnect the throttle position (TP) sensor and the idle air control valve connectors.

    6. Object Number: 1241931 Size: SH
  6. Remove the coolant hoses from the throttle body.
  7. Remove the throttle body retaining bolts.
  8. Remove the throttle body and discard the gasket.
  9. Remove the TP sensor.
  10. Remove the idle air control (IAC) valve.

Installation Procedure

    Object Number: 1241930 Size: SH

    Notice: Use care when cleaning the old gasket from the aluminum surfaces in order to prevent damage to the sealing surfaces.

  1. Clean the gasket mating surface on the intake manifold.

    2. Notice: Do not subject a throttle body assembly which contains the following components to an immersion cleaner or a strong solvent:

       • Throttle position (TP) sensor
       • Idle air control (IAC) valve
       • Sealed throttle shaft bearings
    The cleaners will damage the electric components or sensors.

    The cleaners will damage some of these components that contain seals or O-rings.

    Solvents can wash away or break down the grease used on non-serviceable throttle shaft bearings.

    Never use a wire brush or scraper to clean the throttle body. A wire brush or sharp tools may damage the throttle body components.

    Do not use a cleaner that contains methyl ethyl ketone. This extremely strong solvent may damage components and is not necessary for this type of cleaning.

  2. Clean the throttle body.
  3. Install the TP sensor.
  4. Install the IAC valve.

    5. Object Number: 1241931 Size: SH
  5. Install the throttle body assembly with a new gasket to the intake manifold.

    6. Notice: Refer to Fastener Notice in the Preface section.

  6. Install the throttle body retaining bolts.

    7. Tighten
    Tighten the throttle body retaining bolts to 15 N·m (11 lb ft).

  7. Install the coolant hoses.
  8. Connect the vacuum hoses to the throttle body.

    9. Object Number: 1241566 Size: SH

    Important: Make sure the throttle control cables do not hold the throttle open. With the engine OFF, check to see that the accelerator pedal is free.

  9. Connect the throttle cables.
  10. Install the air intake tube.
  11. Connect the TP sensor connector and the IAC valve connector.
  12. Connect the negative battery cable.
  13. Fill the cooling system.