Coutesy of OZTuscani
This DIY will cover removing the stock Throttle Body (TB) & reinstalling it or replacing it with a BBTB (Big Bore Throttle Body).
Tools Needed:
Pliers
Phillips Screwdriver
12mm Socket, Ratchet, & Short Extension
10mm Wrench
Rags and/or disposable cup
THROTTLE BODY REMOVAL
It never hurts to disconnect the battery, the 10mm wrench is all you need to remove the negative terminal.
First you want to remove the stock air intake from the throttle body. These instructions will work for the AOS or stock style intake which retains the flex-pipe. Any other type of aftermarket intakes MAY need to be removed completely.
Using a Phillips screwdriver, loosen the clamps (on the flex pipe) at the TB and just after the MAF sensor. Unhook the vacuum hose from the flex-pipe and then you can lift the whole flex-pipe out.
![Image]()
Now you have a little more room to work. Next you want to remove the throttle cable and cruise control cable from the linkage attached to the TB. While pushing the throttle arm down (open position) you can get enough slack in the cable to easily remove them (they just pop out).
![Image]()
Unplug both wire harnesses (A, B) attached to the TB by pressing in the metal retaining clip while pushing down.
Using a pair of pliers to crimp the clamp, vacuum hose (C) from the top of the TB. Use caution you may need to clamp the line.
![Image]()
Now take the socket wrench with the 12mm socket (and extension if needed) and remove the 2 bolts, & 2 nuts holding the TB to the intake manifold. Each bolt & nut has a lock-washer so be sure you do not lose them. The bottom bolt and nut also support a mounting bracket for the fuel line. When you pull the TB off, the bracket will come with it.
![Image]()
With the TB loose now, you can easily get to the 2 coolant lines attached to the bottom of the throttle body. Just crimp the clamps and pull the hoses off., keep a rag or cup handy to catch any antifreeze that may spill from them.
![Image]()
Inspect the gasket between the TB & intake manifold, if there are no tears or defects you should be able to reuse it with no problems. If you are unsure, just replace it.
![Image]()
REINSTALLATION
Make sure the gasket is reinstalled. If you are installing a BBTB (or onto a ported intake), you will want to modify the gasket slightly. This is easy, just place the gasket onto the TB or intake and you can trace a line or just remember the difference in diameter. Lay the gasket onto a protected surface. Using a sharp knife carefully trim, enlarging the inside diameter of the gasket.
Now while sliding the TB back onto the 2 studs, slip the left hole in the fuel line mounting bracket over the bottom left stud of the intake manifold. Using your 12mm socket and wrench reattach the 2 bolts (and lock washers) and 2 nuts (and lock washers) that hold the TB to the intake. Make sure the bottom bolt goes through the remaining hole in the fuel line bracket before tightening (Factory Torque is 11-14 lbs/ft).
![Image]()
Using a pair of pliers to crimp the clamp, reconnect the fuel line (1) to the top of the TB. Next, reattach both wire harnesses (2, 3) to the TB.
![Image]()
Now, using the pliers reconnect the 2 coolant lines on the bottom. If you are installing an aftermarket BBTB or prefer to bypass these coolant lines, see here for DIY on this: http://www.newtiburon.com/yabbse/index.php?board=28;action=display;threadid=23041;start=0
Almost done! While pushing the throttle arm down (open position), reconnect the throttle and cruise control cables. Reattach your flex pipe and vacuum hose and tighten both clamps with the Phillips screwdriver. If you have a CAI other than the AOS, the flex pipe will obviously not be used. Once you are done, the finished product should look like this:
![Image]()
Reconnect your battery, start the car and check for any leaks!
Enjoy
-Ryloth
This DIY will cover removing the stock Throttle Body (TB) & reinstalling it or replacing it with a BBTB (Big Bore Throttle Body).
Tools Needed:
Pliers
Phillips Screwdriver
12mm Socket, Ratchet, & Short Extension
10mm Wrench
Rags and/or disposable cup
THROTTLE BODY REMOVAL
It never hurts to disconnect the battery, the 10mm wrench is all you need to remove the negative terminal.
First you want to remove the stock air intake from the throttle body. These instructions will work for the AOS or stock style intake which retains the flex-pipe. Any other type of aftermarket intakes MAY need to be removed completely.
Using a Phillips screwdriver, loosen the clamps (on the flex pipe) at the TB and just after the MAF sensor. Unhook the vacuum hose from the flex-pipe and then you can lift the whole flex-pipe out.
Now you have a little more room to work. Next you want to remove the throttle cable and cruise control cable from the linkage attached to the TB. While pushing the throttle arm down (open position) you can get enough slack in the cable to easily remove them (they just pop out).
Unplug both wire harnesses (A, B) attached to the TB by pressing in the metal retaining clip while pushing down.
Using a pair of pliers to crimp the clamp, vacuum hose (C) from the top of the TB. Use caution you may need to clamp the line.
Now take the socket wrench with the 12mm socket (and extension if needed) and remove the 2 bolts, & 2 nuts holding the TB to the intake manifold. Each bolt & nut has a lock-washer so be sure you do not lose them. The bottom bolt and nut also support a mounting bracket for the fuel line. When you pull the TB off, the bracket will come with it.
With the TB loose now, you can easily get to the 2 coolant lines attached to the bottom of the throttle body. Just crimp the clamps and pull the hoses off., keep a rag or cup handy to catch any antifreeze that may spill from them.
Inspect the gasket between the TB & intake manifold, if there are no tears or defects you should be able to reuse it with no problems. If you are unsure, just replace it.
REINSTALLATION
Make sure the gasket is reinstalled. If you are installing a BBTB (or onto a ported intake), you will want to modify the gasket slightly. This is easy, just place the gasket onto the TB or intake and you can trace a line or just remember the difference in diameter. Lay the gasket onto a protected surface. Using a sharp knife carefully trim, enlarging the inside diameter of the gasket.
Now while sliding the TB back onto the 2 studs, slip the left hole in the fuel line mounting bracket over the bottom left stud of the intake manifold. Using your 12mm socket and wrench reattach the 2 bolts (and lock washers) and 2 nuts (and lock washers) that hold the TB to the intake. Make sure the bottom bolt goes through the remaining hole in the fuel line bracket before tightening (Factory Torque is 11-14 lbs/ft).
Using a pair of pliers to crimp the clamp, reconnect the fuel line (1) to the top of the TB. Next, reattach both wire harnesses (2, 3) to the TB.
Now, using the pliers reconnect the 2 coolant lines on the bottom. If you are installing an aftermarket BBTB or prefer to bypass these coolant lines, see here for DIY on this: http://www.newtiburon.com/yabbse/index.php?board=28;action=display;threadid=23041;start=0
Almost done! While pushing the throttle arm down (open position), reconnect the throttle and cruise control cables. Reattach your flex pipe and vacuum hose and tighten both clamps with the Phillips screwdriver. If you have a CAI other than the AOS, the flex pipe will obviously not be used. Once you are done, the finished product should look like this:
Reconnect your battery, start the car and check for any leaks!
Enjoy
-Ryloth
