2000-04 TB's Install Guide (setup includes; Iceman CAI, and N2O)

TOOLS NEEDED:

• Screwdriver (for CAI)
  8mm, 10mm, 11mm sockets
  13mm, 16mm wrenches ( or just a Crescent Wrench)
  Torx T-20
  3mm, 4mm, 5.5 hex wrenches (Allen Wrench)
  Dremel (or grinder, hacksaw, etc.)
  Beverage of choice :)
  
  
  
  INSTALL TIME:
  
  'Bout an hour

First, take a look at your old TB, Cause you'll never miss it.

Now lets identify some of the parts and move on to the Stock TB removal

First, remove the plugs from the Idle air control (IAC) and the throttle position sensor (TPS), and while you're at it, remove the vacuum lines. My car only had one vacuum line hooked up, the other one had a plug over it. I can't remember if I did this, or if it was like that already....*shrug*. You may have both in you r car.

Next you'll want to unscrew the rubber couplers holding the CAI in, this will make removal of the throttle cable easier. Turn the underside where the throttle cable connects to the TB bracket. There's a small hole with a bit of plastic sticking of the TB bracket. Unhook the cable end from the throttle are.

Now you should be able to pull the TB free, and while you're at it, remove the couplers from the CAI, and the bellows tube from hr CAI as well. It is much easier to re-install this way.

Now that the OLD TB is removed, we need to transfer the sensor and bracket over to the SHINY NEW 60mm TB.

Remove the IAC using a 8mm socket. Be sure to get the little rubber gasket out as well. Be very careful not to but , or tare the gasket. If you do it is going to cast you. If you do. I recommend going to a junk yard.

Next, using a T-20 Remove the IAC, and be sure that you get the O-Ring as well.

Now using a 10mm socket, remove the 3 bolts that holds the bracket on the TB. This step should be leaving you with TWO stripped TB's:

You're just about half way there! Now for the tricky part. The bracket will need to be modified to fit the NEW TB. A small tab needs to be cut off or bent to allow the throttle arm to arc.

As you can see, the piece to put is right where the arm for my N2O micro switch rests. But never fear fellow nitrous users, if you have a similar WOT switch mount you will be able to keep it there. I recommend removing the WOT switch at this point. You now have two choices. First you can cut the tab off as shown in the picture which will be easy. Or you can bend the tab out of the way just in case you ever need to put the stock TB back on as this is the WOT throttle stop for the stock TB. People have done both and they both work fine. If you plan on cutting it a hacksaw, grinder, dremel, or anything that you might have.

Now let's get the newly modified bracket onto the NEW TB. Using a 4mm Hex wrench , screw the new TB onto the bracket. The middle bolt requires some creative movement of the throttle arm to get in place. *DO NOT OVER TIGHTEN THE HEX BOLTS* Keep in mind from here on out that you are using steel hardware on an aluminum piece. Snug is good. If you over tighten, you will strip out the holes in the TB!

As you can see in this pic, the 60mm TB has a little piece of the metal that is perfect for contact on the N20 micro switch. The only modification I did to the switch was to bend the contact arm slightly forward to meet the throttle arm.

Now you're ready for the 2nd vacuum line connection. This one goes to the right of the TPS, which we'll install next. this piece goes on with the help of 13mm wrench. Don't forget to put the plug! unless your car didn't have one. I plan to remove this later on and replace with with a pipe plug from a hardware store of the same diameter. I believe it's 5/16 NPT pipe plug, as for my rubber plug i starting to rot. Also remember to use "Teflon Tape" to seal the plugs, so they do not leak.

let's get the TPS on there. You may notice that the TPS wants to go on crooked, about 5-10 degrees clockwise. Not to worry, just gently twist it into place and use a 2mm hex wrench to get it snugged down. Now you should have everything swapped over.

Now you'll want to get the CAI bellows tube coupler to fit over the outlet side of the TB (smaller sire). this is kind of a pain. the Iceman rubber connector is approximately 2.75" outside diameter, and mine had to stretch to 2,86" to fit over the TB! If you are having a lot of trouble , try removing the TB bracket first, it can get in the way or put the rubber connector near a heater to gently warm it up which will help to loosen it so it can slip on. Fortunately the coupler on the inlet side is plenty big (3" on the Iceman) and should slip right on. Tighten down the clamps and your ready to get it on the car! Be sure all the vacuum lines and plugs get hooked up correctly!

AHHH... A THING OF BEAUTY. now go and DRIVE FAST!

-Jackrabbit