How To: Install BBK Throttle Body and Plenum

BBK Throttle Body and Plenum

Since 1988, BBK has dedicated itself to designing and building cutting-edge, high-performance parts and accessories for the Mustang. BBK is known for offering unmatched value and quality while maintaining an OEM fit and finish.

BBK took a different approach when designing an aftermarket throttle body and plenum for the 4.6L two-valve Mustang GT. Instead of the throttle body and plenum being separate from each other like the factory, BBK combined both in a solid cast piece to offer a clean, simplistic upgrade for your two-valve Mustang GT.

This particular throttle intake, if you must, is constructed from cast aluminum, a direct bolt-on replacement, and will be available in a 73mm and 78mm option. The 73mm throttle intake will only be available in the grey powder-coated finish, whereas you can pick up the 78mm option in either the grey powder-coated or polished finished. Each kit will also include all necessary hardware and installation instructions.

Required Tools

• Socket Set
• Metric Allen Wrenches
• Towels
• Phillips Head Screw Driver

Installation Instructions

1. Before you begin installation, disconnect the negative battery cable.
2. Disconnect the front vacuum lines as well as the Throttle Position Sensor and Idle Air Control Motor electrical connections.
3. Remove the two 10mm bolts securing the EGR Valve to the back of the plenum.
4. Remove the two bolts holding the throttle cable bracket to the plenum.
5. Loosen the hose clamp that secures the coupler to the throttle body and separate the coupler from the throttle body.
6. Remove the five bolts holding the plenum to the intake manifold.
7. Carefully pick up on the throttle body and plenum assembly; remove the throttle cable from the throttle body linkage.
8. If needed, carefully push on the eyelet at the end of the cable to pass it through the throttle body linkage.
9. Remove the throttle cable spring from the throttle body and bracket.
10. Remove the last connected vacuum hose and remove the throttle body and plenum assembly from the car.
11. Take this time to inspect and clean the gasket on the intake manifold.
12. Going back over to the factory plenum, remove the Idle Air Control Motor.
13. Remove the Throttle Position Sensor as well.
14. On your new BBK throttle intake, insert the included Throttle Position Sensor bushing into the opening.
15. Re-position the TPS and re-tighten the previously removed hardware or install the two included Phillips head bolts.
16. Before you install the IAC Motor, tighten one of two included PCV fittings.
17. The larger one will be for 2002-2004 cars and the smaller fitting will be for 1996-2001 Mustangs.
18. Apply thread sealer if it fits your needs, although it is not needed.
19. Do NOT over-tighten the PCV fitting.
20. Ensure the fitting is flush with the machined area for the IAC Motor.
21. Reinstall the IAC Motor with the included gasket and re-tighten the previously removed hardware.
22. Position the new throttle intake back into the car.
23. Reinstall the rear vacuum line and re-attach all hardware that is related to the throttle linkage.
24. Secure the BBK throttle intake to the manifold with the four provided 5mm Allen head bolts.
25. Position the included EGR gasket between the plenum and EGR valve, and re-tighten the two previously removed bolts.
26. Secure the throttle cable bracket to the plenum with two included 4mm Allen head bolts.
27. Do NOT use the factory hardware for these locations.
28. It will protrude through the inside of the plenum.
29. Re-position the silicone coupler and re-tighten the hose clamp.
30. Plug in the TPS and IAC Motor electrical connections as well as the three vacuum lines at the front of the throttle intake.
31. Don’t forget to reconnect your negative battery cable.
32. Double check over everything, and you’re all done!