Throttle Body

This procedure covers the removal and replacement of the throttle body on a 2007 Ram 3500 with the 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

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

Preparation

1. Park vehicle on level ground and engage parking brake
2. Turn ignition to OFF position and remove key
3. Open hood and secure with prop rod
4. Allow engine to cool completely if recently operated
5. Disconnect negative battery cable to prevent accidental electrical issues

Procedure

1. 1

   Remove engine cover
   Remove the plastic engine cover by pulling upward firmly on the cover to disengage the mounting grommets. Set the cover aside in a clean area.
2. 2

   Disconnect intake air temperature sensor
   Locate the intake air temperature (IAT) sensor on the air intake tube near the throttle body. Press the release tab on the electrical connector and carefully pull the connector away from the sensor. Move the harness out of the work area.
3. 3

   Loosen and remove air intake hose
   Loosen the hose clamp securing the air intake hose to the throttle body inlet using a flat-head screwdriver or hose clamp driver. Loosen the clamp at the air filter housing end as well. Remove the air intake tube from the vehicle.
   Torque spec

   Air Intake Hose Clamps3 Nm (2 lb-ft)
4. 4

   Disconnect throttle position sensor
   Locate the throttle position sensor (TPS) electrical connector on the side of the throttle body. Press the locking tab and pull the connector straight off the sensor. Inspect the connector for corrosion or damage.
5. 5

   Remove throttle body mounting bolts
   Remove the four throttle body mounting bolts using an appropriate socket. Keep track of the bolt locations as they may be different lengths. Carefully pull the throttle body away from the intake manifold.
   ⚠Do not allow dirt or debris to enter the exposed intake manifold opening. Cover it with a clean rag if the throttle body will be removed for an extended period.
   Torque spec

   Throttle Body Bolts10 Nm (7 lb-ft)
6. 6

   Remove and inspect gasket
   Remove the old throttle body gasket from the intake manifold mounting surface. Inspect both the throttle body and intake manifold mating surfaces for damage, warping, or excessive buildup. Clean both surfaces thoroughly with throttle body cleaner and a lint-free rag.
7. 7

   Clean or inspect throttle body
   If reusing the throttle body, spray throttle body cleaner on the throttle plate and bore, avoiding the TPS sensor area. Use a clean rag to wipe away carbon deposits. Do not force the throttle plate open manually as this can damage the electronic actuator. If replacing, transfer any necessary components to the new throttle body.
   ⚠Never use carb cleaner or aggressive solvents on the throttle body as they can damage the internal electronics and coatings.
8. 8

   Install new gasket
   Position the new throttle body gasket onto the intake manifold mounting surface, ensuring proper alignment with the bolt holes and air passage. Do not use sealant unless specified by the gasket manufacturer.
9. 9

   Install throttle body
   Carefully position the throttle body onto the intake manifold, aligning it with the gasket and bolt holes. Start all four mounting bolts by hand to ensure proper threading. Tighten the bolts in a criss-cross pattern to the specified torque to ensure even gasket compression.
   Torque spec

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

    Reconnect throttle position sensor
    Reconnect the TPS electrical connector to the throttle body, ensuring it clicks into place securely. Verify the locking tab is fully engaged.
11. 11

    Reinstall air intake hose
    Position the air intake hose onto the throttle body inlet and the air filter housing outlet. Ensure the hose is fully seated on both ends. Tighten both hose clamps to the specified torque.
    Torque spec

    Air Intake Hose Clamps3 Nm (2 lb-ft)
12. 12

    Reconnect intake air temperature sensor
    Reconnect the IAT sensor electrical connector, ensuring it clicks securely into place. Verify the locking tab is fully engaged.
13. 13

    Reinstall engine cover and reconnect battery
    Reinstall the engine cover by aligning the mounting grommets and pressing down firmly until seated. Reconnect the negative battery cable to the battery terminal.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify all hose clamps are tightened to specification
3. Double-check that no tools or rags were left in the engine compartment

Verification

• Start the engine and allow it to idle, listening for any air leaks around the throttle body
• Verify the engine idles smoothly without surging or hesitation
• Check for diagnostic trouble codes (DTCs) using a scan tool and clear any codes related to the throttle body if replacement was performed
• Test drive the vehicle to confirm normal throttle response and operation
• Perform a visual inspection after the test drive to ensure no air leaks have developed at the throttle body or intake hose connections

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

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