GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 1999 🢒 SL2/SC2/SW2 🢒 Engine 🢒 Engine Controls - 1.9L 🢒 Throttle Body Assembly Replacement

Removal Procedure

    Object Number: 903521 Size: SH
  1. Disconnect the negative battery terminal.
  2. Remove the air intake tube and fresh air hose.
  3. Disconnect the electrical connectors at the idle air control (IAC) valve and the throttle position (TP) sensor.
  4. Disconnect the vacuum harness.
  5. Disconnect the throttle control cable.

    6. Object Number: 903503 Size: SH
  6. Remove the throttle body retaining bolts.
  7. Remove the throttle body assembly.

    8. Object Number: 903508 Size: SH

    Notice: Cover the intake manifold opening with a shop towel whenever the throttle body is removed to prevent foreign material entry.

  8. Block the intake manifold opening with a clean shop towel to prevent dirt from entering.
  9. Remove the flange gasket and discard.
  10. Remove any old gasket material from the intake manifold.

Installation Procedure

    Object Number: 903660 Size: SH
  1. Inspect the manifold opening and remove any loose parts and/or material.
  2. Inspect the intake manifold sealing surface for cleanliness.
  3. Remove the LOCTITE® gasket sealer from the bolt threads. Remove the shop towel from the throttle body opening and install a new flange gasket.
  4. Install the throttle body assembly. If a new throttle body is used, the idle stop screw on the new unit is preset by the manufacturer and should not require adjustment.
  5. Apply LOCTITE® 242 Threadlocker P/N 21485277 or equivalent to the attachment bolt threads. Install the throttle body assembly retaining bolts.

    6. Tighten
    Tighten the bolts to 31 N·m (23 lb ft).

  6. Install the throttle control cable.
  7. Connect the vacuum harness.
  8. Connect the IAC valve and throttle position (TP) sensor electrical connectors. Push in until a click is heard and pull back to confirm positive engagement.
  9. Connect the negative battery terminal.
  10. Install the air intake tube and air box cover.
  11. Start the engine and check for vacuum leaks.