MAC Performance Throttle Body & Intake Plenum with Spacer (Cont'd)
Before remove 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 throtlle 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 need to re-use this gasket on the new intake chamber.
With all the extremities free, we can remove the 5 bolts holding the intake chamber.
Careful 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.
Carefully position the newly assembled intake chamber over the intake manifold and start threading the 4 mounting bolts, leaving them loose. Since we have added an adaptor plate, there is a small spacer that is supplied to put under the support leg of the intake chamber. 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.