HowTo:
Upgrade from a 46mm to a 52mm TB.

Disclaimer: I (the author) am in no way responsible for what you do to your vehicle. This web page is in no way affiliated with Daimler-Chrysler. All opinions, technical information, or otherwise are to be taken as is and at your own risk. That said, let's get started!
I am sure you'll find this operation a very simple task. I was afraid to open the hood when I bought my car and now I do all sorts of things like this. Anyway firstly, you must have the right tools, you'll need:
NOTE: If you don't plan on replacing the gasket just be careful when pulling the throttle body away from the plenum, if it's really old it can rip. Then you'll need a new one anyway.

Once you have this stuff, look under the hood for a fat (about 1 to 2 inch hose) that makes a U-turn shape. Use the screwdriver to take off the hose clamps on both ends of the hose. Remove the hose from the engine compartment. Now, you should be able to look into the TB... small isn't it?

Now you have to disconnect the throttle cables from the bracket, it's an easy task. Just pull the throttle back to WOT (wide open throttle) position and slide the little cylindrical ends out of the throttle block. Here's what it looks like:

Removing the throttle cables

Once they are completely out of the throttle block, just let them hang there.
NOTE: if you don't have cruise control there will only be one throttle cable

Throttle cables off

Then next thing to do is remove the throttle cable brackets from the throttle body bracket, use the pliers to push the flaps together on either side of the cable brackets and press the cables through the throttle body bracket. See here:

Removing the throttle brackets

Looking at this picture you can see the plan of action. All the items with a blue circle you must disconnect. See the following paragraph for the explanation...

All the stuff to unplug

At the top, there is a brake vacuum booster line, just pull it off. Next is the TPS (Throttle Positioning Sensor) it has a plug with a hook on it, pull the hook up and pull the plug out. After those are done on the very bottom is the AIS (Automatic Idle Speed) sensor, it's a plug just like the TPS, unplug it too. Now, if you have a cable loop like I do on my car (in green) then you should open it up and swing it down so it's not holding the cable.

Now unscrew these!

After unplugging all that stuff, use your socket wrench, 13mm socket and the extension to remove the two TB-to-plenum bolts circled in red. Once you remove those you can completely remove the throttle body from the engine compartment. Like I stated before be careful when doing this if you don't have a replacement gasket, if you rip it you'll get a vacuum leak (not good).

Unscrew the screws holding the bracket

Once you have the throttle body seperated, you'll probably need the bracket off of it (I did), just remove the two bolts (circled in red). And replace it onto the new throttle body. Piece of cake!


Installation is reverse of removal (you see I put that at the end of all my how to's because it saves me from typing everything again.)

Don't forget the gasket between the plenum and the throttle body and don't forget to plug in the two sensors and the brake booster... all of these things are very important.


Spikey's HowTo ThrottleBody page has been hit 180 times since January 22, 2001.

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