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BBK 65mm Throttle Body (99-2000 V6) - Installation Instructions

Installation Time

60 minutes

Tools Required
  • 3mm Allen Wrench
  • 5mm Allen Wrench
  • 10mm Ratchet and Socket
  • 8mm Ratchet and Socket
  • Flat Head Screw Driver
  • Phillips Head Screw Driver
  • Rubber Hammer or Mallet
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1. Disconnect the negative or black wire from the battery. This makes it possible for the all the cars systems to reset.
2. Disconnect the hose that runs from the air intake to the engine. Loosen the hose clamp from the throttle body and the MAF. Remove the part of the air intake that connects to the old throttle body. If your car has a two (2) piece air intake you can remove just the top half.

3. Disconnect the Throttle Position Sensor, located on the left side of the throttle body, by removing the two (2) screws on the top and bottom of the sensor.

4. Disconnect the throttle cable and auxiliary return cable. The auxiliary return cable pops off with pressure and the throttle cable has a space in the bottom where it can be slid off easily.

5. Unbolt the four (4) nuts holding the old throttle body.

6. The throttle body on my car was stuck on pretty good and a few hits from a rubber mallet made it pop right off.

7. After removing the old throttle body, gently clear any debris from where the throttle body was contacting the intake manifold. DO NOT clean inside the intake manifold unless there is a large clump of debris that you know shouldn’t be there.

8. Place the supplied throttle body base gasket onto the manifold.

9. Install the new throttle body onto the manifold. I used the bolts supplied on the top left corner and bottom right corner of the throttle body where the whole bolt was removed. I also used a lock nut to remove the bolts that the nuts came off of on the top right and bottom left. I tightened the lock nut until the screw spun with the nut the removed the screw and replaced it with the included hardware. DO NOT tighten one bolt all the way at once but do each one evenly in a circular fashion to ensure and even tightening.

10. Put the Throttle Position Sensor onto the new throttle body.

11. Check the bolts on the throttle body one more time.

12. Reconnect the throttle cable and auxiliary return cable.

13. Reinstall the air intake, this step will require some pushing and the use of a flathead screw driver to make the hose coupling fit the throttle body, and reconnect any wiring that became disconnected. Replace the tube that runs from the air intake tithe engine.

14. Tighten all the hose clamps that were loosened.

15. Reconnect the negative battery cable to the battery.

16. Start the car and it is recommended that you let the car get to its normal operating temperature before driving to ensure that all electrical sensors have time to reset to the new throttle body.

17. If your car does not start properly, after idling until the engine is at its normal operating temperature, you will have to adjust the idle screw located under the red circle in the picture above. You may need to open the throttle body by pushing the screw against the throttle body to open the throttle butterfly more by using the 3mm Allen wrench. This should fix any start up problems you may encounter.

Installation instructions provided by AmericanMuscle customer Killian Voigt 6.27.09

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