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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The following pages contain technical guidelines for custom body manufacturers/ coachwork specialists for construction and assembly of custom body-related parts and conversions. The body assembly guidelines should be strictly adhered to if modifications are made with the intention of doing so. Included in the Volkswagen body assembly guidelines are also the body dimension plans for our commercial vehicles Crafter, Transporter T4 and T5, Caddy and LT. These can be installed in 3 formats (TIF, DXF, IGES) for CAD programs and as PDF files. Advice: If further technical queries about the series production vehicle arise over and beyond these guidelines, please contact your local conversion expert at your importer.
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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 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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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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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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Proper installation of this kit requires knowledge of the factory recommended procedures for removal and installation of original equipment components. We recommend that the factory shop manual and any special tools needed to service your vehicle be on hand during the installation. Installation of this kit without proper knowledge of the factory recommended procedures may affect the performance of these components and the safety of the vehicle. We strongly recommend that a certified mechanic familiar with the installation of similar components install this kit
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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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Installation Instructions. Read Me! Rv. 01/04
1. DISCONNECT NEGATIVE (-) BATTERY CABLE.
2. Remove throttle body air intake system.
3. Remove (3) nuts & studs from the throttle body & manifold. (Ref. “C”)
4. Remove support bracket from engine block to throttle body. (Ref. “D”)
* Please Note: When removing support bracket bolt at engine block, loosen bolt enough to remove bracket. DO NOT REMOVE BOLT.
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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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