GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Generic 🢒 2003 🢒 Unit Repair 🢒 Engine 🢒 Engine Controls - 4.8L, 5.3L, and 6.0L 🢒 Throttle Body Assembly Replacement

Removal Procedure

    Notice: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type.

    Important: An eight digit part identification number is stamped on the throttle body casting. Refer to this number if servicing, or part replacement is required.

  1. Partially drain the cooling system in order to allow the hoses at the throttle body to be removed.

    2. Important: Cover or plug any openings when servicing the throttle body in order to prevent possible contamination.

  2. Remove the air intake duct.

    3. Object Number: 825837 Size: SH
  3. Disconnect the throttle actuator motor harness connector.
  4. Disconnect the coolant hoses from the throttle body.
  5. Remove the throttle body attaching bolts.
  6. Remove the throttle body and the gasket.

    7. Important: Do not reuse the throttle body gasket. Install a new gasket during assembly.

  7. Discard the throttle body gasket.
  8. Inspect the crankcase ventilation hose and the tube. Replace any damaged components.

Installation Procedure

    Object Number: 825837 Size: SH
  1. Install a new throttle body gasket.
  2. Install the throttle body assembly.

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

    Important: Always use a torque wrench in order to obtain the proper torque.

  3. Install the throttle body attaching bolts.

    4. Tighten
    Tighten the throttle body bolts to 10 N·m (89 lb in).

  4. Connect the coolant hoses to the throttle body.

    5. Important: Verify that the TAC harness connector and the connector seal are properly installed and not damaged.

  5. Connect the TAC harness connector.
  6. Install the air intake duct.
  7. Connect the intake air temperature sensor harness connector.
  8. Refill the cooling system.
  9. Verify that the vehicle meets the following conditions:
    10. • The vehicle is not in a Reduced Engine Power mode.
    • The ignition is ON.
    • The engine is OFF.
  10. Connect a scan tool in order to test for a proper throttle-opening and throttle-closing range.
  11. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT).
  12. Start the engine.
  13. Inspect for coolant leaks.