These instructions are based on my experience with removing and cleaning the throttle body and from information obtained from the 2000 Durango Factory Service Manual. They were originally my notes for use when I have to do it again. They are as complete and detailed as I can make them, however they are provided for informational purposes only and you should follow or use them at your own risk! Other year models may be different; other engines ARE different. If something on yours seems different, it may well be! Use your head and be careful.
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Included with your Poweraid Spacer is a sticker with a California Air Resources Board (C.A.R.B.) Executive Order (EO) number. This sticker must be placed in plain view inside of the engine compartment. Failure to do so may prevent you from passing a smog inspection.
Installation Procedure:
1. DISCONNECT NEGATIVE (-) BATTERY CABLE.
2. Remove air cleaner assembly.
3. Using 1/2” socket, remove (4) 5/16” bolts attaching throttle body to manifold.
4. Lift throttle body.
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Installation Procedure for this body spacer:
1. DISCONNECT NEGATIVE (-) BATTERY CABLE.
2. Remove throttle body air intake assembly.
3. Remove (2) nuts from the throttle body and (2) studs from manifold. (Ref. “C”)
4. Remove gasket and clean surfaces.
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Installation Instructions Procedures:
1. DISCONNECT NEGATIVE (-) BATTERY CABLE.
2. Remove air intake assembly.
3. Remove throttle body intake box and save bolts.
4. Remove (3) bolts from throttle body.
5. Remove bolts from throttle linkage bracket and save.
6. Install power plate using (3) 6mm x 60 bolts and (3) 6mm flat washers. (Ref. “A”)
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The mounting procedure outlined below covers the 2000 – 2004 Dodge Dakota trucks. You will need to refer to the illustrations and familiarize yourself with each of the undercarriage components and their relative position to each other. Then proceed as follows:
1. Disconnect fog lamps from bumper if equipped on vehicle.
2. Cut rubber portion of air deflector attached to bumper and discard. Open vehicle hood and remove four vertical bumper bolts from existing Bumper Brackets (BB). Remove bolts from two outer bumper brackets if equipped on vehicle. Remove bumper.
3. Clamp existing Bumper Bracket (BB) to frame rail. Remove two existing Nuts (AA) from Bumper Bracket (BB). Use chisel and hammer between head of existing Bolts (CC) and Bumper Bracket (BB) to force them loose. Use caution to prevent damage to parts. Unclamp and remove Bumper Bracket (BB). Repeat process on opposite side of vehicle.
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The installation instructions step:
1. DISCONNECT NEGATIVE (-) BATTERY CABLE.
2. Remove air cleaner housing from throttle body.
3. Remove 5/16” bolt (Ref. “C”) & stud (Ref. “D”) from throttle body.
4. Remove (2) 6mm bolts from throttle linkage bracket and save.
5. Move the throttle body forward then remove the gasket and clean the surfaces.
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This undercarriage fits all models listed but the cross member connection will vary. Refer to step “a” for the 1987–96 Dodge Dakota, 1997–03 Dodge Dakota Sport, 1997–03 Dodge Dakota SLT Extended Cab and 1998–03 Dodge Durango SLT models. Refer to step “b” for the 1997–04 Dodge Dakota and 1998–03 Dodge Durango.
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This undercarriage fits all models listed but the crossmember connection will vary. Refer to step “a” for the 1987-1996 Dodge Dakota, 1997-2003 Dodge Dakota Sport, 1997-2003 Dodge Dakota SLT Extended Cab and 1998-2003 Dodge Durango SLT models. Refer to step “b” for the 1997-2004 Dodge Dakota and 1998-2003 Dodge Durango
1. Disconnect the fog lamp harnesses if applicable, and then remove the bumper.
a. Remove the bumper mount plates from in between the frame rail and radiator. Discard the mount plate hardware.
b. Permanently remove the air dam from the truck frame crossmember. Remove the fasteners that are pressed into the bumper bracket on the frame rail. Secure the bracket and frame wall with vise grips and then use a hammer to punch out the fasteners.
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Step of the Installation Instructions:
1. DISCONNECT NEGATIVE (-) BATTERY CABLE.
2. Loosen the hose clamp and remove the air tube from the throttle body air box.
3. Disconnect the air temperature sensor connector attached to the air box.
4. Loosen the two bolts that secure the air box using a 10mm socket.
5. Remove the oil filler cap (for clearance if needed) and carefully pull and remove the air box. * Be careful not to drop anything in the oil filler pipe.
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The installation instructions step:
1. Disconnect the negative battery cable! Loosen two hose clamps and remove the air intake tube. Separate the intake tube from the plastic clamp on the upper radiator hose. (If equipped).
2. Using a 10mm socket, remove the three nuts that hold the throttle body to the intake manifold.
3. Using a 4mm socket, remove the three studs that go thru the throttle body into the intake manifold.
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