GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Aveo 🢒 Engine 🢒 Engine Controls - 1.2L 🢒 Throttle Body Assembly Replacement

Removal Procedure

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


    Object Number: 1348527 Size: SH
  1. Disconnect the negative battery cable.
  2. Disconnect the positive crankcase ventilation (PCV) hose.
  3. Release the clamp bolts from the air outlet hose.
  4. Remove the air outlet hose.

    5. Object Number: 1348528 Size: SH
  5. Disconnect the throttle cable from the mounting bracket.
  6. Disconnect the throttle cable by opening the throttle and moving the cable through the release slot.
  7. Remove the retaining nuts from the throttle cable bracket.

    8. Object Number: 1348531 Size: SH
  8. Disconnect the throttle body electrical connector.
  9. Disconnect the coolant water hoses.
  10. Remove the throttle body retaining bolts.

Installation Procedure

    Object Number: 1348532 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 throttle body assembly with a new gasket to the intake manifold.

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

  4. Install the throttle body retaining bolts.

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

  5. Install the coolant water hoses.
  6. Connect the throttle body electrical connector.

    7. Object Number: 1348528 Size: SH

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

  7. Connect the throttle cable.

    8. Object Number: 1348527 Size: SH
  8. Connect the PCV hose.
  9. Connect the air outlet hose.
  10. Tighten the clamp bolts.
  11. Connect the negative battery cable.