2.0L Zetec 65mm Throttle Body
Part #1751
INS-078
Step 1
Raise hood and disconnect negative (–) battery terminal.
Step 2
Unclamp and remove air cleaner inlet tube between the throttle body and air box.
Step 3
Unplug the throttle position sensor, located on the right side of the throttle body when facing the engine.
Step 4
Disconnect the throttle and cruise control cables from the throttle linkage.
Step 5
Remove the (3) three bolts attaching the throttle/cruise control cable bracket to the throttle body.
Step 6
Remove the (4) four mounting screws attaching the throttle body to the intake manifold, then carefully remove
the throttle body from the vehicle.
Step 7
Remove the throttle position sensor from the stock throttle body and attach to the BBK throttle body using the
new supplied hardware. (The sensor will sit at a different angle, however, the relationship between the sensor and
the throttle shaft are engineered to be the same so that the proper voltage will remain at the sensor.)
Step 8
Install the new supplied paper type gasket onto the manifold (do not use the factory rubber gasket) and reinstall
the new BBK throttle body onto the intake manifold. (Great care must be used to not cross-thread or over tighten
the self-threading screws attaching the throttle body to the manifold.)
Step 9
Reassemble and reinstall all components in reverse of disassembly.
Step 10
Reinstall negative (–) battery terminal.
Step 11
Start vehicle without touching the accelerator pedal and allow the vehicle to run until full operating temperature is
achieved. If the idle speed after this period of time is incorrect, a slight adjustment of the set screw setting the
position of the throttle linkage may be made using a 3mm Allen wrench.
INSTALLATION INSTRUCTIONS
www.BBKPERFORMANCE.com
IMPORTANT—All appropriate safety equipment (e.i., gloves, tools) must be used during the installation of this product(s).
BBK Performance, Inc. accepts no responsibility for injuries resulting in the installation of any product(s).
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