dsg_gt2004

The main reason I made this is because i couldnt find any directions online, so I made my own. Hope they help.)



First off, Check the stock piece and look around and get familiar with everything that is on the stocker. This will help in the future when you have to put everything back together again. Also, make sure you unplug your battery.

Next up, Take the TPS harness, throttle cable, and cruise control cables off

Here is a pic of the TPS harness which you press the button and pull up. Next to it is a pic of the throttle and cruise control assembly. To remove just undo the slack in the throttle cable(just pull it from under that black piece, and then move the metal end piece
to the left. The cruise control cable is simply snapped upward. Make sure to remove the bracket holding the cables on the plenum off.

Now, lets get the PCV hoses off, take all the ones that are connected to the throttle body and plenum. Here are pics of the the red one, and the one in the rear(simply pull them off)

Now it's time to get the EGR off. Unbolt it , remove the gasket(don't reuse, kit should have come with new one). Here is a pic of the EGR

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Now that you got all the hoses off(make sure to take the main hose that connect your intake system to the throttle body off), UNBOLT the plenum, which only consists of 5 bolts. Now, we are going to transfer a few pieces from the old to the new. But, until then lets look at a comparison of the old and new.

Here is a front comparison


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Here is a comparison of the insides of the plenums(Note how stock piece is burred and rough while Accufab is really smooth)


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Ok, now the REALLY FUN part, GETTING the stock TPS off..
For some this is really hard, I lucked out and had one easy screw and 1 hard to remove screw. The key is getting a phillip end that fits snuggly, and apply as much pressure as you can in the screw while you turn it. This will reduce the risk of stripping. But, if you are unfortunate, just get a dremel or something out and sand it off. Here is a pic of the TPS and my one troublesome screw. My kit came with new allen head screw which made tightening simple and future removal alot easier.

The other piece that is to the right of the TPS simply unbolts. Just trash the old gasket and use the new one provided. This part also should have new allen head bolts. Just bolt that on and then you're one step closer to being finished.

Go ahead and stick the new piece on the intake manifold and loosely bolt it down with the stock 5 bolts. Then reattach all the previous hoses and cable and harnesses. Make sure not to miss the rear PCV valve. Use the stock bolts (with stock washers) and attach the EGR valve back on.If you forgot where one goes, just refer to your stock piece to get a hint where it seems it would go.


It would also be a good idea to check the stock piece while you install everything back to make sure you dont miss anything. Another HARD part may be when attaching the intake tube to the throttle body. If you have any trouble you will need two things, PATIENCE and something like vaseline. Just rub some on the throttle body and the tube and slowly work it on. It took me around 10 minutes to get on. Make sure you tighten everything down and put your battery terminal back on. Crank your car up and let it idle for about 5 minutes so your computer can relearn the air system.



-from my cardomain site, page 5(has more pictures)

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2004 Dark Shadow Grey Premium GT/Dark Charcoal leather/5 speed
354.2 rwhp/360.6 rwtq
HEAT KILLS POWER
My Cardomain Website ||updated 7/24/05

USMCstang

Good writeup...those TPS screws are definitley a pain huh? I edited your title to conform with the rest of the threads, but left your writeup completely intact.

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~Mike
98 GT 4R70W
Buckeye Stangs - Ohio Based Mustang Enthusiasts

dsg_gt2004

thanks, yeh, i had that one screw i almost stripped and i luckily got it out by applied all my weight and then turning it...thanks for the title change too

__________________
2004 Dark Shadow Grey Premium GT/Dark Charcoal leather/5 speed
354.2 rwhp/360.6 rwtq
HEAT KILLS POWER
My Cardomain Website ||updated 7/24/05