‘04-07 5.4L F150 3V 80mm Throttle Body
Part #1759
INS-109
w w w . B B K P E R F O R M A N C E . c o m
I N S T A L L A T I O N I N S T R U C T I O N S
STEP 1
Disconnect negative battery terminal. If these instructions are followed closely, this will
prevent the CHECK ENGINE light from coming on after the installation.
STEP 2 Unplug the mass air meter by sliding the red colored locking clip back, and then squeezing the
tab on the wiring connector while pulling it away from the air box.
STEP 3 Disconnect the PCV tube by gently twisting the green locking tab and pulling the tube away from
the air box.
STEP 4 Remove the 4 bolts that attach the air lter box to the intake manifold and the 1 bolt that attaches
it to the bracket near the power steering reservoir. Lift the box up away from the throttle body, and pull the
tube away from the fender wall. Remove the air box from the vehicle.
STEP 5 Unplug the throttle body electric motor and TPS by sliding the red colored locking clips back, and
then squeezing the tabs on each wiring connector while pulling them from their connections.
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 the T-20 Torx remove the motor housing, plastic capped spring, and TPS from the stock
throttle body. Note: plastic capped spring will be under tension load. You will be
re-loading the spring in STEP 11. When removing the TPS, lift it straight up off of the throttle body. Do
not twist or rotate the TPS
STEP 8 Pop the removable circular cap off of the motor housing (
this is easily done with a nger
)
STEP 9 Place the plastic capped spring over the end of the throttle shaft of the BBK throttle body and line
the pigtail hook on the spring up with the catch slot in the gear.
STEP 10 Install the motor housing minus the removable cap onto the BBK throttle body over the plastic
spring cap and tighten screws.
STEP 11 Using needle nosed pliers rotate the plastic spring cap
COUNTER CLOCKWISE (approximate-
ly 180°
) until the 2 tabs line up with their matching landings in the motor housing, then gently pull up on
the cap until it pops up into a latched position.
STEP 12 Align the tabs on the removable cap with the slots on the motor housing and snap it into place.
STEP 13 Install the TPS onto the BBK throttle body by lining up the locating tab and tightening the
screws.
The TPS does not need to be rotated or “clocked”
.
STEP 14 Check the throttle body for smooth action by opening and closing the ap a few times with your
ngers. You should feel a slight drag from the electric motor, but it should never bind up or stick.
STEP 15 Install the throttle body onto the intake manifold using the 4 supplied screws, then re-establish
the wiring connections.
ATTENTION!
All BBK throttle bodies are pre adjusted and tested during assembly.
If you have any problems with this throttle body call our Tech Support
DO NOT ATTEMPT TO MAKE ANY ADJUSTMENTS.
TOOLS REQUIRED
1/4” Ratchet T-20 Torx
1/4” Extension Needle nose pliers
8mm socket & 10mm deep socket 5mm Allen wrench
(1 pages)
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