Dragon Performance Throttle Body & Intake Adapter (Cont'd)
Before removing the 5 mounting bolts that secure the intake chamber to the intake manifold, we need to free up the throttle/cruise control linkage. There are 2 bolts that secure a bracket to the top of the intake chamber. Remove the spring return from the bracket first, then loosen the bolts. The cruise control linkage is the plastic lined connection, it will just snap off of the connector point on the throttle body. Grasp the throttle body and open the throttle, this will allow you to get some slack in the throttle cable and remove it from it's mount.
It is now time to remove the vacuum line, electrical connection for the throttle positioning sensor and the AIC motor from the intake chamber. mounting bolts for the intake chamber. The vacuum hose may require a little persuasion with a screw driver or pry tool. Be careful when removing the AIC motor to prevent damage to the gasket. You will not need to re-use this gasket but you can if you want to on the new intake adapter.
With all the extremities free, we can remove the 5 bolts holding the intake chamber.
Carefully lift up on the stock chamber, there is a rubber ring gasket that seals it to the intake manifold. Once it is free, it will allow you to remove the emission hose on the back side of the chamber.
We found it easier to mate the 75mm throttle body to the new chamber first utilizing the supplied gasket as well as the adaptor for the 2001/2002 PCV valve. This is done by putting a smaller 3/8" hose over the fitting, then the larger stock tube over the smaller tube. A hose clamp in supplied by Dragon Performance for a secure attachment.
Carefully position the newly assembled intake chamber over the intake manifold and start threading the 4 mounting bolts, leaving them loose. The Dragon Adapter does not have the stabilizing leg like the stock chamber so you will have one extra mounting bolt to save. Carefully tighten in a opposing pattern, the mounting bolts. DO NOT OVER TIGHTEN THESE BOLTS. They are mounted in a plastic intake manifold, over torque these bolts and you could crack or strip out the threaded inserts.
Reassemble the AIC motor, the EGR Valve with a new gasket and tighten the pipe fitting securing the pipe. Reconnect the vacuum feed and transfer the throttle positioning sensor (TPS) from the old throttle body onto the new throttle body and reconnect the wiring harness to the TPS and AIC motor. Don't forget the Evaporative Emission Return hose on the back side of the chamber. Reconnect the throttle/cruise control linkage and spring return. Check to see that there is full motion and operation of this linkage with not interference. Re-install the intake tube and tighten the hose clamps should complete your installation. Check for any tools, stock part or fasteners lying around the engine compartment before closing the hood.
Start the engine and check for any vacuum leaks. Let it idle for a few minutes until the engine actually warms up. This will allow the computer to learn a few things about the new mixtures that is needs to compensate for. Take it for a short drive, driving normally without pushing any limits. After a few miles, give it a test and feel the new response and torque you will feel. This is another good Seat of the Pants install. Enjoy.