INS047
POWER-PLUS SERIES 66mm
THROTTLE BODY
1989-02 FORD
RANGER/EXPLORER
PART# 1580
STEP 1
Disconnect the negative battery terminal.
STEP 2
Remove flexible inlet tube from the throttle body and air box by loosening the two clamps.
Disconnect the tube to the valve cover and the Inlet Air Temp Sensor, if applicable.
STEP 3
Remove the plastic cover on the left side of the throttle body. Unhook the throttle/cruise
cables from the throttle body. Disconnect the Throttle Position Sensor (TPS) electrical
connector and unhook any vacuum lines.
STEP 4
Remove the four (4) bolts that mount the throttle body to the intake manifold. Remove the
Throttle body and clean any gasket material from the mounting surface.
STEP 5
Remove the Throttle Position Sensor from the old throttle body. You will probably need a
Impact screwdriver to remove the screws due to the use of Locktite on the threads from
the factory. If screwheads become rounded, then they must be carefully ground off to
remove the sensor.
STEP 6
Install the supplied BLACK TPS BUSHING over the shaft of the throttle body, install
Throttle Position Sensor ontop of the bushing and secure sensor with the supplied screws.
FOR OPTIMUM PERFORMANCE
Match the intake opening to he new throttle body size. Although
this is not mandatory, it will maximize intake flow.
STEP 7
Using the supplied screws and gasket, install the BBK throttle body on to the intake opening.
Tighten screws.
STEP 8
Reattach the throttle/cruise cables, reconnect the TPS connector and vacuum hose.
STEP 9
Reinstall the flexible air inlet tube between the air box and the throttle body. Reconnect the
breather hose to the valve cover and reinstall (or connect) the Inlet Air Temp sensor,
if applicable.
NOTE
On some models with a black composite intake manifold, a short piece
of 5/32” vacuum hose and a FORD part # N802484-5100 will be needed
for the emissions/vacuum connection on the bottom of the throttle body.
Trim ¼” off the non-barbed end of the fitting to work properly.
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 Inc. accepts no responsibility for injuries or damage caused by or during the installation of this product.
(1 pages)
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