GM Service Manual Online
For 1990-2009 cars
Makes 🢒 Chevrolet 🢒 2004 🢒 Tahoe - 2WD 🢒 Engine 🢒 Engine Controls - 4.8L, 5.3L, and 6.0L 🢒 Throttle Body Assembly Replacement

Removal Procedure

Notice: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type.

Important: 

   • DO NOT for any reason, insert a screwdriver or other small hand tools into the throttle body to hold open the throttle plate, as the wedge inside the throttle body could be damaged.
   • An 8-digit part identification number is stamped on the throttle body casting. Refer to this number if servicing, or part replacement is required.


    Object Number: 1235686 Size: SH
  1. Partially drain the cooling system in order to allow the hose at the throttle body to be removed. Refer to Cooling System Draining and Filling in Engine Cooling.
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
  3. Remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
  4. Disconnect the throttle actuator motor electrical connector (2).

    5. Object Number: 1239286 Size: SH
  5. Reposition the coolant air bleed hose clamp at the throttle body.
  6. Remove the coolant air bleed hose from the throttle body.

    7. Object Number: 825837 Size: SH
  7. Remove the throttle body nuts.
  8. Remove the throttle body.

    9. Object Number: 492774 Size: SH
  9. Remove and discard the throttle body gasket (1).

Installation Procedure

    Object Number: 492774 Size: SH
  1. Install the NEW throttle body gasket (1).

    2. Object Number: 825837 Size: SH
  2. Install the throttle body.

    3. 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.

  3. Install the throttle body nuts.

    4. Tighten
    Tighten the nuts to 10 N·m (89 lb in).


    Object Number: 1239286 Size: SH
  4. Install the coolant air bleed hose to the throttle body.
  5. Position the coolant air bleed hose clamp at the throttle body.

    6. Object Number: 1235686 Size: SH

    Important: Verify that the throttle actuator motor harness connector and the connector seal are properly installed and not damaged.

  6. Connect the throttle actuator motor electrical connector (2).
  7. Install the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
  8. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
  9. Refill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  10. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range.
  11. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT).
  12. Verify that the vehicle meets the following conditions:
    13. • The vehicle is not in a reduced engine power mode.
    • The ignition is ON.
    • The engine is OFF.
  13. Start the engine.
  14. Inspect for coolant leaks.