4bangerjp.com
General Forums => Technical Archive => Topic started by: FourbangerYJ on January 12, 2009, 09:36:35 AM
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Tools needed
10mm socket
Flathead screwdriver
T20 tamper proof torx
Total time about 2 hours give or take
(http://i30.photobucket.com/albums/c331/FourbangerYJ/001-2.jpg)
Started by removing the throttle cable,hand throttle cable and the return spring. Also removed the air cleaner tube. I also disconnected the battery.
(http://i30.photobucket.com/albums/c331/FourbangerYJ/002-1.jpg)
Next I unpluged the TPS and AIS motor. They are the 2 bigger plugs on the left side.
(http://i30.photobucket.com/albums/c331/FourbangerYJ/003-1.jpg)
This is the 4.0 TB I took off. The dark line is the outside diameter of the gasket which is 62mm. Kinda gives you an idea of how much bigger the 62mm TB is.
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(http://i30.photobucket.com/albums/c331/FourbangerYJ/004.jpg)
I marked the intake with a sharpie using a new gasket as a guide. I used the 10mm bolts to hold the gasket while I marked it.
I measured the stock intake at 55mm.
(http://i30.photobucket.com/albums/c331/FourbangerYJ/005-2.jpg)
This is after I switched the AIS motor and the TPS to the 62mm TB. Gives you and idea of the bigger size.
(http://i30.photobucket.com/albums/c331/FourbangerYJ/009.jpg)
I stuffed the intake opening with some rags then smeared on some grease hoping to keep the chips out of the intake.
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(http://i30.photobucket.com/albums/c331/FourbangerYJ/010.jpg)
I used a Dremmel with a rotary rasp to remove the material from the intake. With a new cutter it goes pretty fast! I looked all over for a 2 inch drum sander to finish the grinding with. But none of the hardware stores in my area had any.
(http://i30.photobucket.com/albums/c331/FourbangerYJ/011-2.jpg)
Here it is all ground out. I checked it with the new gasket.
The most time was taken getting all the chips out of the intake. Those chips get everywhere! If I had to do it again I would have used some blue painters tape and put it on the inside of the intake. In my haste I did not notice that there are 4 hole that are just under the TB. I would have taped them off. It took quite a few Q-tips to remove the chips from in there. The towels and grease did help keeping the chips out of the runners of the intake.
I put it all back together and fired it up. It started up and ran fine. After a few minutes the idle kicked down to normal RPS's.
I have not had a chance to drive it yet. The winds today are crazy strong. I will post back when I get a chance to drive it.
THANKS Bounty Hunter for the quick service on the TB and the advice. You too Jeffy!