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Discussion Starter #1 (Edited)
How-To: Clean Throttle Body (Staging Area)

Throttle Body Cleaning
2004 Dodge Ram 5.7 Liter - 80,0000 Miles

The general concept will likely apply to any late model DC vehicle

Difficulty level: Easy - Moderate

Approximate Time Required:
2 Hours


Optional Parts: Intake Air Temperature Sensor (IAT), PCV Valve

Tools Required: (I happen to have an aftermarket CAI. If you have the Stock HEMI breather hat, you will need the necessary tools to remove it as well)
- #2 Flathead Screwdriver
- 1/4" Rachet
- 1/4" extension
- 8mm socket (1/4)
- 5/16th Socket (1/4) or equivalent Nut-driver
- 3 Cans of Brake Cleaner (DO NOT USE Throttle Body Cleaner!!!!!!!!!!)
- Several Clean Shop Towels (Lint Free)
- 1 Toothbrush or similar sized non-abrasive scrub brush

Special Note: Additionally, if you have ever experienced spontaneously erratic throttle jerking, stalling while driving, etc, that seems to just show up for no reason and completely solve itself after a restart, Try this... If you have experienced this, you will have likely also gotten the following DTC:

P2175 - Throttle Actuator Sys - Low Airflow Detected

Preface: We will be intimately cleaning the throttle body, that on this particular truck is actuated via Electronic Throttle Control (Drive by Wire). EXTREME CARE must be taken to avoid damaging any electronics, sensors, etc. This isnt meant to scare you, just to warn you. As you will see, this is very easy to do if you are well armed with cleaner and know how to use a screw driver.
 

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Discussion Starter #2
Step 1: Determining what you will need to remove the Intake

Take a minute to thoroughly look over your intake system. Make note of all your sensors, Wires, retention brackets, etc, and make certain you have the appropriate tools. In My case, I have a K&N CAI as shown here. Pretty much all I needed to remove the CAI was a Flat Head screw driver and a 5/16th socket periodically.
 

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Discussion Starter #3
Step 2: Removing the Air Filter

In my case, I simply removed the K&N Filter Clamp with the 5/16th socket and slid the Filter element Off of the CAI tube, and set it aside on a clean surface
 

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Discussion Starter #4
Step 3: Removing the CAI Tube From Throttle Body

Once again, This is where the "How-To:" will vary from one application to another. Use common sense and determine what steps will be necessary to remove enough of the air-box system so that you have easy access to the throttle body.

Here you can see, once again, I simply removed the connecting clamps that hold the plastic CAI tube to the forward opening of the Throttle Body.
 

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Discussion Starter #5
Step 3: Removing the CAI Tube From Throttle Body

BEFORE you go yanking the top of your engine apart. Make note of a couple of connectors you need to remove to avoid damage.

FIRST (in my case) was the easiest. I simply used a flathead screwdriver to "break the seal" of a Vacuum line attached to my CAI and was able to pull it free with very little effort.
 

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Discussion Starter #6
Step 3: Removing the CAI Tube From Throttle Body

The next thing to watch out for is the Intake Air Temperature Sensor, Commonly referred to as the IAT. Special care should be taken because this sensor is VERY fragile.

In My case, and in most others, you will probably not have to physically remove this sensor from your CAI Tube / Hemi Hat. You will likely be able to simply unplug it.

(***NOTE: If you are using Nicks =Air=Ram=> Power Wire, go ahead and remove it completely now)


If you have ever worked on anything with a motor, you should be able to figure this out. Depress the Locking key and wiggle the IAT Sensor harness plug from the sensor
 

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Discussion Starter #7
Step 3: Removing the CAI Tube From Throttle Body

Go ahead and take a second to look closely and make sure everything is dsconnected and the entire intake system free.

***NOTE:
If you have loosened all the bolts and left them in their proper holes, PLEASE go ahead and take them ALL out before you attempt to pull the intake system off the top of the engine. THE LAST THING you want is to drop a nut or bolt into the throttle body / Intake.

Now, gently remove the remainder of your intake. It would be a good idea to have a partner watching closely as you do this because forgotten items still attached will quickly be noticed by that extra pair of eyes.

In my case, I employed the services of my 8 Year old son Aaron.
 

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Discussion Starter #8
Step 4: Removing the Throttle Body

Call me Paranoid, but I have had to pull an intake manifold NUMEROUS times because that "One tiny piece" of something or the other managed to slip out of my hand and into the engine.

Do yourself a HUGE favor and take a lint free towel, fold it up, and cram it into the T-body opening to prevent this.

Now, before anyone flames me, These particular Terry Cloth towels are usually heavily lint-laden. HOWEVER, I have washed these shop towels NUMEROUS times and I assure you, they are as lint free as they come after 30 washings.

I would recommend driving up to PetBoys and buying some of those old "Cloth diapers", but I didnt happen to have any.
 

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Discussion Starter #9
Step 4: Removing the Throttle Body

Once the Throttle Body opening is secured, Go ahead and look around your work area and secure all loose dangling harness connectors that we have removed to this point. Once we start the next step, your gonna need all of your hands and those loose dangling wires just get in the way.

If your Throttle Body is a "Drive By Wire system, you will find somewhere, a harness plug that supplies current for the motor and other essential signals passed from the computer tot he T-Body.

On the 04 and like HEMI's, this plug is located on top, in the front of the T-Body as shown here.

***NOTE: This connector doesn't work like ones you may be used to. you DO NOT push the tab to remove the plug, You will use a screw driver to pull the tab slightly away from the connector (to the rear of the plug) and this will unlock it, allowing you to remove the T-Body harness plug.
 

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Discussion Starter #10
Step 4: Removing the Throttle Body

Again, Make sure you tuck the Harness Connector out of the way.

The Next step is to identify the Bolts we need to remove to physically take the throttle body OFF of the intake manifold.

On The HEMI, You will fine VERY easily which they are. There are four 8mm bolts located at each corner of the T-Body and they face forward. You cant miss them. They have been painted GREEN:
 

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Discussion Starter #11
Step 4: Removing the Throttle Body

Using a 1/4" Rachet, attach a 6" extension and an 8mm Socket.

Loosen AND REMOVE the bolts one at a time using a criss-cross pattern. Top-Right, Bottom-Left, Top-Left, Bottom-Right.

These Intakes are plastic and you want to keep the torque stress on the intake as even as possible to avoid any possibility of over stressing one particular area, resulting in a possible crack in the intake.

Once you have all four bolts removed, the throttle body will literally fall into your hand:
 

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Discussion Starter #12
Step 5: Drink a Beer & Freak Out at What You See

Once you have the TB in your hands and sitting on your work area, Crack open a frosty-cool-adult-beverage and when your have a swig or two, Flip it over to the back side.

If you have been cussing this whole time wondering WHY you are doing this... Take a look. Notice the Coking around the Butterfly edge and seat possition.. UNREAL!
 

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Step 5: Drink a Beer & Freak Out at What You See

Pretty rough eh?

Now hold your breath and look at the BACK side of it:


/FAINT


WHO THE HELL Rhino-Lined the BACK SIDE OF MY THROTTLE BODY!?!?!?! :VHOT: :VHOT: :VHOT: :VHOT:
 

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Discussion Starter #14
Step 5: Drink a Beer & Freak Out at What You See

Also notice the Coking found in the Intake Manifold. We will address this later.

DO NOT SPRAY ANYTHING into the intake manifold. If you do, when you start your truck, It will Blow the Intake manifold OFF and into the next Zip Code.
 

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Step 6: Cleaning the Throttle Body

Now that we have a couple cold beers in us and are done freaking out. Its time to do what we set out to do... CLEAN the nasty SOB.

For this, USE BRAKE CLEANER. Im sure we could start a completely new thread debating on what works best, but this is what I used. Good Ol Napa Brake Cleaner.

Once again, DO NOT USE THROTTLE BODY CLEANER! Not even the MOPAR BRAND. Based on the TSB that I did this after, even THEY say to use BRAKE CLEANER ONLY because it evaporates fast, and wont damage the sensitive sensors and electronics on board the T-Body

Do yourself a HUGE favor and grab 4 cans. I used three completely and a 4th would have been nice.

Also Get a Tooth brush handy because you will need it, I assure you!

Last but most important, DO NOT ATTEMPT THIS WITHOUT SAFETY GLASSES. I PROMISE YOU, there is NO WAY your going to clean this thing without inadvertently reverse blasting yourself in the eyeball... and yes, I speak from experience, and THAT $HIT BURNS!!!!!!!
 

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Discussion Starter #16
Step 6: Cleaning the Throttle Body

The first thing to remember before we get to blasting away is this:

Gravity is not just a good idea, IT'S THE LAW

1. Now, Grab the T-Body and hold it with actuator motor UP so the cleaner has less chance of soaking the electronics.

2. Hold the T-Body as far away from your body as possible and start blasting. The majority of the Coking will wash right away. After one can of blasting on the dirty side, here is what mine looked like:
 

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Step 6: Cleaning the Throttle Body

Dont fret. By now you have seen that Brake cleaner is some SERIOUSLY mean $hit. The Coking should be stripping off and pouring out of the T-body with every squirt. Dont be scared. Pretend your Blasting the 4 inches of caked mud off of your truck after a mud trip.

When you can see that your spraying is no longer doing much Good, Its time to get the brush out...

Spray a little, Brush a little, Spray a little, Brush a little.

I have heard that you DO NOT want to press open the butterfly valve. Personally, I threw caution to the wind and pushed it almost fully open and using spraying and brushing, cleaned it spotless. The Butterfly is spring loaded and will close back just fine. Keep at it until it is clean...
 

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Discussion Starter #18
Step 6: Cleaning the Throttle Body

Once your done, allow it to sit and dry. REMEMBER, Keep the Motor Side of the TB facing UP at all time. Better to be safe than sorry.

Once your finished, it should look like this....
 

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Step 6: Cleaning the Throttle Body

In case you didnt catch it in the picture above. I wanted to point out something that I noticed.

IF YOU LIVE IN THE SOUTH PAY ATTENTION!!!!!

Notice here... See the odd looking pattern on the butterfly? At first glance it would look like scuffs... Its not.. That is CONDENSATION. After a 15 minute soak down session with COLD ASS brake cleaner, the Ambient HUMID air is condensating on the metal surface. MAKE SURE you keep an eye on this. Until the TB reaches ambient air temp, you will want to keep drying it to avoid excess moisture in the TB.
 

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Discussion Starter #20
Step 7: MORE CLEANING!

While we have everything torn apart, Lets take the opportunity to clean EVERYTHING. As bad as that T-Body looked, common sense would tell us everything ELSE involved has to be JUST as dirty.

1. With a lint free towel. SOAK the PISS out of it, and CAREFULLY and GENTLY clean as much of the Intake opening as you can.

2. I also wanted to clean my Intake Tube. Note here, that the IAT sensor is still installed. GENTLY remove the IAT....
 

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