Throttle Body

This procedure covers removal and installation of the throttle body on a 2005 Dodge Viper 8.3L V10 engine, including disconnecting intake ducting, electrical connections, and coolant lines.

Warnings

Tools required

Parts

• Throttle body gasket × 1 — Use OEM specification
• Throttle body (if replacing) × 1 — Use OEM specification

Fluids

• Zerex G-05 HOAT 50/50 — 1 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Allow engine to cool completely (minimum 2 hours after last operation)
3. Disconnect negative battery cable to prevent accidental throttle plate movement
4. Place drain pan beneath engine to catch coolant spillage

Procedure

1. 1

   Remove air intake duct
   Loosen the hose clamp at the throttle body inlet using a flathead screwdriver or hose clamp pliers. Loosen the clamp at the air filter housing end. Remove the intake duct by pulling it free from the throttle body and air filter housing. Set aside.
2. 2

   Disconnect throttle body electrical connector
   Locate the electrical connector(s) on the throttle body, including the Throttle Position Sensor (TPS) and any idle air control (IAC) motor connector. Press the release tab on each and pull the connector straight off. Move the wiring harness aside to provide clearance.
3. 3

   Disconnect throttle cable and cruise control cable
   Locate the throttle cable and cruise control cable attached to the throttle body lever. Unhook the cable ends from the throttle lever by rotating the lever to create slack, then sliding the cable ends out of their slots. Disengage the cable housings from their bracket by pressing the retaining tabs and pulling the cables through. Move cables aside.
4. 4

   Disconnect coolant bypass hoses
   The throttle body has two small coolant bypass hoses connected to it for cold-weather operation. Position drain pan beneath these connections. Use hose clamp pliers or flathead screwdriver to move the spring clamps back away from the throttle body on both hoses. Twist and pull each hose off the throttle body nipples. Expect approximately 4-8 oz of coolant to drain from each connection. Plug hose ends with shop towels to minimize further spillage.
   ⚠Coolant will spill when hoses are disconnected. Ensure drain pan is positioned correctly.
5. 5

   Remove throttle body mounting bolts
   Remove the 4 bolts securing the throttle body to the intake manifold. These are located at the corners of the throttle body mounting flange. Use a socket and ratchet to remove all bolts completely. Keep bolts organized for reinstallation.
6. 6

   Remove throttle body
   Carefully pull the throttle body straight away from the intake manifold. The gasket may stick to either the throttle body or manifold surface. Once removed, inspect the throttle body bore and throttle plate for carbon buildup or damage. If cleaning only, proceed with throttle body cleaning procedures before reinstallation.
7. 7

   Clean gasket surfaces
   Remove and discard the old throttle body gasket. Thoroughly clean both the intake manifold mounting surface and the throttle body mounting surface using a plastic scraper and shop towels. Remove all old gasket material and ensure both surfaces are clean and dry. Do not use metal scrapers that could damage the sealing surfaces.
8. 8

   Install new throttle body gasket
   Position the new throttle body gasket onto the intake manifold mounting surface. Ensure the gasket is properly aligned with all bolt holes and coolant passages. The gasket should sit flat without any wrinkles or folds.
9. 9

   Install throttle body
   Carefully position the throttle body onto the intake manifold, aligning it with the gasket and ensuring all bolt holes line up. Insert all 4 mounting bolts finger-tight to hold the throttle body in position. Once all bolts are started, use a torque wrench to tighten them in a crisscross pattern to specified torque.
   Torque spec

   Throttle Body Bolts10 Nm (7 lb-ft)
10. 10

    Reconnect coolant bypass hoses
    Push each coolant bypass hose firmly onto its respective throttle body nipple until fully seated. Slide the spring clamps back into position over the hose connections, ensuring they are positioned approximately 1/4 inch from the hose end and secure the hose to the nipple.
11. 11

    Reconnect throttle and cruise control cables
    Insert the throttle cable and cruise control cable housings back into their bracket until the retaining tabs click into place. Rotate the throttle lever and hook each cable end back into its slot on the lever. Verify both cables have free movement and return to idle position when released.
12. 12

    Reconnect throttle body electrical connector
    Push the TPS electrical connector firmly onto the throttle body until it clicks into place. Verify the connector is fully seated and the locking tab is engaged.
13. 13

    Reinstall air intake duct
    Position the air intake duct onto the throttle body inlet and air filter housing. Ensure the duct is fully seated on both ends. Tighten both hose clamps securely, but do not overtighten.
    Torque spec

    Air Intake Hose Clamps3 Nm (2 lb-ft)
14. 14

    Refill and bleed cooling system
    Reconnect the negative battery cable. Check the coolant level in the radiator overflow reservoir and add Zerex G-05 HOAT 50/50 coolant as needed to bring to the proper level. Start the engine and allow it to reach operating temperature with the heater on maximum to purge air from the cooling system. Monitor coolant level and add as necessary. Check for coolant leaks at the throttle body hose connections.

Reassembly

1. Torque all throttle body mounting bolts in a crisscross pattern to ensure even gasket compression and prevent warping
2. Verify all coolant hose clamps are positioned correctly and secure before starting engine
3. Cable routing should match original installation to prevent binding or interference

Verification

• Start engine and verify smooth idle with no hunting or surging
• Blip throttle several times to verify immediate throttle response and return to idle
• Check for coolant leaks at both throttle body coolant hose connections
• Verify no air leaks at throttle body gasket or intake duct connections (listen for hissing)
• Test drive vehicle to confirm normal throttle operation and cruise control function
• Recheck coolant level after test drive when engine is cool

Related trouble codes on this vehicle

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