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How to install an Accufab 70mm Throttle Body & Plenum Combo on your 1996-2004 Mustang GT

Installation Time

2 hours

Tools Required
  • Ratchet
  • Ratchet Extension
  • 5/16" or 8mm Socket
  • 3/8" or 10mm Socket
  • Phillips Screwdriver
  • 1/8" Hex Key
  • Hammer
  • Loctite 243 (blue) or equivalent
  • Gasket Scraper or Putty Knife
  • Shop Vacuum (not shown)
View PDF Guide


PROCEDURE


1. With the ignition in the OFF position and the key removed. Loosen & disconnect the negative battery terminal.



2. Loosen the air intake tube clamps (5/16” or 8mm) at the Throttle Body (TB) inlet and Air Filter box, remove tube while disconnecting the 2 auxiliary connections from the air intake tube.


3. To prevent contamination, protect the air intake tube openings.


4. Remove the Idle Air Control (IAC) valve (2 x 5/16” or 8mm) & hose from the TB plenum. Then remove and clean any gasket material from the IAC and tape to prevent contamination.


5. Remove the Positive Crankcase Ventilation (PCV) hose from the TB plenum.


6. Remove the vacuum (red) lines from the TB plenum; be gentle, as these lines can become brittle over time.


7. Disconnect the throttle linkage spring at both ends and remove.


8. Gently twist & pull the hose to remove from the rear of the TB plenum.


9. Remove the throttle cable support (1 x 5/16” or 8mm), then disconnect the cable from the TB linkage by unwrapping it from its track and sliding the ferrule from its pocket. Note: if your car is equipped with cruise control, this will need to be disconnected at this time.


10. Remove the throttle cable support bracket (3 x 3/8” or 10mm) from the TB plenum intake manifold.


11. Remove the Exhaust Gas Recirculation (EGR) valve (2 x 3/8” or 10mm) from the driver side of the TB plenum. Note: the EGR valve is connected directly to the driver side exhaust manifold/header by a steel tube, and will have limited movement.


12. Disconnect the electrical connector from the Throttle Position Sensor (TPS), then remove the TPS (2 x Philips screws) from the TB.



13. Remove the TB (5 x 5/16” or 8mm) from the intake manifold.


Instructions supplied from Accufab:


Supplied are two PCV tubes. Depending on the year your car was made, please select and install the correct tube accordingly.


After selecting the correct tube, place a small amount of “Lock-Tite” on the end. Gently tap this end into the hole with a hammer.

14. Select the correct PCV tube and install into the TB as per the supplied instructions.


Instructions supplied from Accufab:


IDLE CONTROL


Idle speed can ONLY be set by adjusting the throttle position sensor. DO NOT adjust any screws on the throttle body. The screws are pre-set at the factory.

15. Install the TPS onto the TB using the new supplied screws (2 x 1/8” hex key); torque 25-34 LB-IN.


16. Using a clean cloth, cover the intake manifold opening to prevent contamination.


17. Clean all old gasket material from the EGR valve sealing surface. Using a vacuum, clean all dirt and debris around the intake manifold opening.


18. Remove the cloth from the intake manifold opening and install the new TB, reusing the original bolts (5 x 5/16” or 8mm); torque .


19. Using the new gasket supplied with the TB, reinstall the EGR valve, reusing the original bolts (2 x 3/8” or 10mm); torque 15-22 LB-FT.


20. Using the new gasket supplied with the TB, reinstall the IAC valve, reusing the original bolts (2 x 5/16” or 8mm); torque 71-106 LB-IN.


21. Reinstall the vacuum lines onto the new TB plenum.


22. Reattach both the TPS & IAC electrical connectors.


23. Reinstall the throttle cable support bracket (3 x 3/8” or 10mm); torque .


24. Reattach the hose to the rear of the TB plenum. Note that the TB tube is slightly different than stock, but the original hose easily bends to accommodate the new routing.


25. Reconnect the IAC hose to the IAC valve.


26. Reconnect the PCV hose to the TB plenum.


27. Reattach the throttle linkage spring.


28. Insert the throttle cable ferrule into its pocket, then wrap the throttle cable around the underside of the TB linkage, making sure it site properly in the track.


29. Reinstall the throttle cable support (1 x 5/16” or 8mm); torque 46-63 LB-IN.


30. Reinstall the air intake tube, tighten both clamps (2 x 5/16” or 8mm); torque 21-28 LB-IN, and reconnect both auxiliary hose connections.


Installation Instructions Written by AmericanMuscle Customer David Princz 06.10.2014

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