BBK INS092 Throttle Body User Manual
- May 15, 2024
- BBK
Table of Contents
INS092 Throttle Body
User Manual
Part # 1757 // 2003 – 2006 GM 4.8L, 5.3L, 6.0L Truck & H2
INSTALLATION INSTRUCTIONS – INS092
ELECTRONIC THROTTLE CONTROL (ETC) – 80MM
THROTTLE BODY
INS092 Throttle Body
SPECIAL TOOLS REQUIRED: 1/4″ Ratchet, 6″ Extension /4mm and 8mm Short Sockets
/ 10mm Deep Socket / T-25 Torx / 5mm and 4mm Allen Wrenches / Pliers Vise
Grips (recommended) / Phillips Screwdriver / Drill with a 3/16″ Bit.
INSTALL TIME: Approximately 1 hour.
DIFFICULTY: Easy.
CAUTION! This installation involves disconnecting coolant hoses. Be sure
to give the engine plenty of time to cool before beginning.
FOLLOW THESE INSTRUCTIONS CAREFULLY TO ENSURE CORRECT FITMENT AND OPERATION
HARDWARE INCLUDED
BBK throttle body, 3 Allen head mounting bolts, and 4 Phillips head screws,
Puller tool (2 Allen heads, and 2 self tapping screws).
REMOVAL
STEP 1
Disconnect negative (–) battery terminal.
STEP 2
Remove decorative cover from top of intake.
STEP 3
Separate the coolant hose retaining clip from the bottom of the intake air
inlet hose, loosen the hose clamps at the throttle body, and at the mass air
meter.
Remove the intake hose assembly from the vehicle.
STEP 4
Unplug the throttle body electric motor by removing the gray colored locking clip, and then squeezing the tab on the wiring connector while pulling it from the motor housing.
STEP 5
Using pliers remove the coolant pass through hoses from the bottom of the
throttle body by squeezing the tabs on the hose clamps together and pulling
the hoses away from the throttle body.
NOTE To prevent the spillage of coolant, we recommend gently clamping vise
grip type pliers onto the hoses before removing.
STEP 6
Unbolt and remove the throttle body.
NOTE Be careful not to damage the throttle body motor housing as you will be
re-using it.
STEP 7
Using a 4mm socket remove the throttle body mounting studs from the intake
manifold.
FOLLOW THESE INSTRUCTIONS CAREFULLY TO ENSURE CORRECT FITMENT AND OPERATION
INSTALLATION
STEP 1
Using a drill with a 3/16 bit CAREFULLY drill out the rivets that attach the
throttle body motor housing to the throttle body.
STEP 2
Remove the motor housing from the throttle body by gently and evenly prying
the plastic housing up from the throttle body.
STEP 3
Remove the round idler gear from the throttle body.
NOTE Rotation orientation is not critical on assembly.
STEP 4
Using a T-25 Torx, unbolt the motor from the throttle body.
STEP 5
Using the puller tool remove the motor.
NOTE To use the puller; lay it flat over the top of the motor. Put the self-
tapping screws through the small puller holes and tighten them with a ºîsocket
into the small holes on top of the motor until the screw heads touch the
puller. Insert the 4mm Allen heads into the threaded holes on the puller and
tighten them evenly against the throttle body. This will pull the motor
straight up and out. The BBK throttle body is designed to accept the motor
with or without the circular clip.
STEP 6
Install the motor into the BBK throttle body and tighten the Torx bolts.
STEP 7
Install the idler gear onto the BBK throttle body insuring engagement onto the
other gears.
STEP 8
Install the motor housing, be sure to note the electrical contacts.
Be careful not to bend them while sliding the housing into place.
Insert and tighten the supplied Phillips head screws around the housing.
INSTALLATION
STEP 1
Connect the coolant pass through hoses to the BBK throttle body.
STEP 2
Using a 5mm Allen wrench and the supplied bolts, install the throttle body
onto the intake manifold.
STEP 3
Plug in the throttle body motor wiring connector, and re-insert the gray
retaining clip.
STEP 4
Re-install the intake air inlet hose and attach the coolant hose to the
locating clip.
STEP 5
Re-install the decorative intake cover.
STEP 6
Connect negative battery cable.
STEP 7
Start your engine and let it idle completely uninterrupted for approx. 20
minutes before driving. This will give the engine management computer time to
adapt to the BBK throttle body at normal operating temperatures.
IMPORTANT: All appropriate safety equipment and gear must be used during
the installation of this or any BBK Performance products or any time you work
on a vehicle.
BBK Performance accepts no responsibility for injuries or damage caused by or
during the installation of this product.
UPDATED LAST: March 2019
MADE IN U.S.A.WWW.BBKPERFORMANCE.COM
BBK PERFORMANCE LLC
3060 Performance Circle
Deland, FL 32724
For any questions, email us:
[email protected]