See the warning at the beginning of the section Relieving pressure in the power supply system of gasoline engines.
Engines 1.6 l SOHC
1. Relieve residual pressure in the supply system (see Relieving pressure in the power supply system of gasoline engines). Disconnect the negative cable from the battery.
2. Loosen the clamp.
3. Disconnect the intake air duct from the throttle body cover (don't forget to remove the gasket).
4. Also disconnect from a cover air and vacuum hoses, turn out fixing screws and remove a cover with a sealing ring from the top part of the case of a throttle.
5. Release the clamps, disconnect the position sensor electrical wiring connectors (potentiometer) throttle valve (TPS), stepper motor and injector. Move the wiring aside.
6. Disconnect fuel hoses from the throttle body.
7. Disconnect the accelerator link from the pivot on the throttle body.
8. Disconnect air and vacuum hoses from the throttle body.
9. Give nuts of fastening of the case of a throttle to the inlet pipeline and remove knot together with a sealing lining. The gasket must be replaced during assembly.
10. If necessary, unscrew the clamping screws (with TORX sockets) and divide the throttle body into two parts. Remove and discard the sealing gasket - the gasket must be replaced during reassembly without fail.
11. Make sure that the mating surfaces are absolutely clean and dry, replace the gasket and assemble the throttle body. Lubricate the threaded part of the fixing screws with an anaerobic sealant before screwing in. Tighten the screws to the required torque in several steps.
12. Make sure that the mating surfaces of the throttle body and intake manifold are absolutely clean and dry, remove all traces of old sealant from the threaded parts of the nuts and mounting studs / bolts.
13. Lay a new gasket on the pipeline, install the throttle body on top. Lubricate the threaded part of the fixing nuts with an anaerobic sealant. In several steps, tighten the fasteners with the required force.
14. Restore the original connection of the vacuum and air hoses, connect the throttle actuator rod to the hinge.
15. Connect fuel hoses to the throttle body. Tighten the union nuts with the required force. Restore the original wiring connection.
16. After replacing the O-ring, reinstall the throttle body cover. Install and securely tighten the cover screws, then connect the intake duct and vacuum hoses.
17. Connect the negative wire to the battery. Start the engine and check the components of the power system for signs of leaks before leaving.
Engines 1.4 and 1.6 l DOHC
1. Relieve residual pressure in the supply system (see Relieving pressure in the power supply system of gasoline engines). Disconnect the negative cable from the battery.
2. Remove the oil filler cap. Turn out fixing screws and remove a protective casing of the engine. Screw the oil filler cap into place.
3. Disconnect the wiring from the intake air temperature sensor (IAT), disconnect the intake duct from the air cleaner and throttle body, - on Zafira models, it will be necessary to remove the sealing strip of the engine compartment and the reflector mounted under the windshield. In order to provide access to the intake duct, give the fixing nuts and bolts, the front panel cover.
4. Disconnect the charcoal canister purge valve hose from the left side of the intake manifold.
5. Release the latch and disconnect the tip of the cable from the throttle actuator lever. Release the cable sheath from the support bracket and move the cable aside.
6. Turn out fixing bolts and remove the case of a throttle from the pipeline. Remove and discard the sealing gasket - it must be replaced during assembly without fail.
7. Turn the throttle body so that you can get close to the cooling system hoses. Apply identification marks, loosen mounting clamps and disconnect both hoses - plug open hose ends immediately to minimize coolant loss.
8. Disconnect the electrical wiring from the TPS sensor and the idle speed stabilization system stepper motor, then remove the throttle body from the engine compartment.
9. Installation is done in the reverse order to the dismantling of the components. Pay attention to the following points:
- Before installing the throttle body on the manifold, make sure that all wires and hoses are connected to it correctly.
- Don't forget to replace the gaskets (first make sure that the mating surfaces are absolutely clean and dry), and make sure all fasteners are tightened to the correct torque.
- Track correctness of a laying and reliability of fixing of all hoses.
- Finally, adjust the throttle cable (see Removing, installing and adjusting the throttle cable - petrol models).
Engines 1.8 and 2.0 l
1. Disconnect the negative cable from the battery.
2. Remove the oil filler cap. Turn out fixing screws and remove a protective casing of the engine. Screw the oil filler cap into place.
3. Disconnect the electrical wiring from the air mass sensor (MAF).
4. Release the clamps and disconnect the intake air duct together with the sensor from the air cleaner and throttle body, - on Zafira models it will be necessary to remove the sealing strip of the engine compartment and the reflector installed under the windshield. In order to provide access to the intake duct, give the fixing nuts and bolts, the front panel cover.
5. Release the latch and disconnect the tip of the cable from the throttle actuator lever. Release the cable sheath from the support bracket and move the cable aside. On models equipped with a speed control system, it is also necessary to disconnect the tempostat drive cable - the tip of the cable is connected to the throttle actuator lever pivot using a locking bracket.
6. Turn out fixing bolts and remove a basic arm of a cable from the case of a throttle.
7. Release the mounting clamps and disconnect the crankcase ventilation hose from the timing cover and throttle body.
8. Clamp both hoses of the cooling system connected to the throttle body with clamps, disconnect them after loosening the clamps. Wipe up any spilled coolant immediately with a rag.
9. Disconnect the fuel tank ventilation hose from the throttle body.
10. On 2.0 l models disconnect the wiring harness from the throttle position sensor (TPS) and idle speed control valve. On engines 1.8 l disconnect the electrical wiring from the throttle valve.
11. Disconnect all remaining vacuum and air hoses from the throttle body - try to remember the order of connecting the hoses. Remove the TORX head screws and remove the throttle body from the intake manifold.
12. Remove and discard the sealing gasket - the gasket must be replaced during installation without fail.
4. Installation is done in the reverse order to the dismantling of the components. Pay attention to the following points:
- Before installing the throttle body on the manifold, make sure that all wires and hoses are connected to it correctly.
- Don't forget to replace the gaskets (first make sure that the mating surfaces are absolutely clean and dry), and make sure all fasteners are tightened to the correct torque.
- Track correctness of a laying and reliability of fixing of all hoses.
- Finally, adjust the throttle cable (see Removing, installing and adjusting the throttle cable - petrol models).
Adaptation of the new throttle body to the ECM is carried out in a workshop using special diagnostic equipment.
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