GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Geo 🢒 1996 🢒 Metro 🢒 Engine 🢒 Engine Controls - 1.0L 🢒 Throttle Body Assembly Replacement

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Remove the air cleaner (ACL) from the throttle body fuel injection (TBI) unit. Refer to Air Cleaner Assembly Replacement .

    3. Object Number: 157841 Size: SH
  3. Disconnect the throttle position (TP) sensor electrical connector.
  4. Disconnect the fuel injector electrical connector.

    5. Object Number: 157845 Size: SH
  5. Disconnect the idle speed control (ISC) motor electrical connector.

    6. Object Number: 157846 Size: SH
  6. Disconnect the one clamp and the fuel feed hose from the TBI unit.
  7. Disconnect the one clamp and the fuel return hose from the TBI unit.
  8. Disconnect the vacuum hoses from the TBI unit.

    9. Object Number: 158273 Size: SH
  9. Loosen the accelerator cable locknut (1).

    10. Object Number: 158276 Size: SH
  10. Rotate the throttle lever (1) to the wide open position.
  11. Remove the cable end from the slot in the throttle lever.

    12. Object Number: 158280 Size: SH
  12. Remove the accelerator cable (1) from the cable bracket.

    13. Object Number: 157847 Size: SH
  13. Remove the four bolts and the TBI unit.

Installation Procedure
  1. Install the new gasket onto the early fuel evaporation (EFE) heater.

    2. Object Number: 157847 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the TBI unit to the EFE heater and secure with the four bolts.

    3. Tighten
    Tighten the TBI unit bolts to 23 N·m (17 lb ft).


    Object Number: 166628 Size: SH
  3. Install the accelerator cable to the cable bracket.
  4. Rotate the throttle lever to the wide open position.

    5. Object Number: 166631 Size: SH
  5. Install the cable end (1) into the slot on the throttle lever.
  6. Connect the vacuum hoses to the TBI unit.

    7. Object Number: 157846 Size: SH
  7. Connect the fuel return hose to the TBI unit and secure with the clamp.
  8. Connect the fuel feed hose to the TBI unit and secure with the clamp.

    9. Object Number: 157845 Size: SH
  9. Connect the ISC motor electrical connector.

    10. Object Number: 157841 Size: SH
  10. Connect the fuel injector electrical connector.
  11. Connect the TP sensor electrical connector.
  12. Connect the negative battery cable.

    13. Tighten
    Tighten the negative battery cable terminal retainer to 5.5 N·m (4 lb ft).

  13. Turn ON the ignition in order to pressurize the fuel system.
  14. Turn OFF the ignition.
  15. Check for fuel leaks.
  16. Adjust the accelerator cable. Refer to Accelerator Cable Adjustment .
  17. Adjust the TP sensor. Refer to Throttle Position Sensor Adjustment .