5/16" Nut Driver

10mm Socket

Ratchet

Pliers

T30 Torx

Normal 0

Bostig v2.0 Intake Sub-Kit
SK-I

Reverse the Throttle Position Sensor by removing the two screws that hold it to the throttle body and pulling it straight outward.  Spin the sensor 180 degrees and push it back onto the throttle body.  Reinstall the screws and tighten until snug.

Remove the O-ring from the throttle body and discard.  This O-ring may not provide a complete seal to the aluminum intake extension, so it will not be used.  Apply a small bead of RTV around the perimeter of the throttle body where the O-ring was previously installed and to the mating face of the aluminum intake extension.  Assemble the throttle body onto the aluminum intake extension so the idle air bypass tube lines up with the elongated idle air bypass port on the throttle body.  Secure with four M6x20 bolts and lock washers.  Torque to 89 inch/pounds.

Apply a thin film of RTV to the face of the intake manifold and to the bottom face of the aluminum intake extension.  It is important to seal completely around the idle air bypass port on the intake manifold and the intake extension.

If it is not already in place, install the aluminum Intake Hose Breather Assembly into the hole in the rubber intake hose and tighten the nut until nice and snug. 

Install a #52 hose clamp to the end of the intake hose with the aluminum breather assembly nipple and then push the hose down onto the throttle body.  Before tightening the clamp completely, position the rubber intake hose so the aluminum breather assembly nipple faces the black nipple coming off the valve cover on the engine.  Place the silicone breather tube between the aluminum nipple on the intake hose and the black nipple on the valve cover.  Trim breather tube to proper length if necessary.  Tighten #52 hose clamp on intake hose.

Route the intake hose along the rear lip of the engine compartment so that it will not interfere with any moving parts.  General routing would be under the coil, behind the thermostat and around the outside of the engine bay to the passenger side tail light area.

Slide a #52 hose clamp over the open end of the intake hose and push the hose onto the mass airflow meter, which will be attached to the airbox or filter setup of your choice.  Tighten hose clamp.

Secure the intake hose to the firewall of the van with zip ties to prevent any unnecessary movement.

Bostig strongly reccomends replacing all fuel lines in the van with 3/8” (or 5/16" if available) high pressure fuel injection hose.  For a complete fuel line
replacement 2WD vans will require approximately 16-18 feet, Syncros will require approximately 8-10 feet depending on year and model.  DO NOT use the stock plastic fitting on the firewall when reinstalling your fuel lines.  It is a well known source of failure and is not well suited for proper routing to the Zetec fuel rail. 

Remove the brass block off plate from the flywheel (front of van) side of the Zetec fuel rail and replace it with the aluminum barbed fuel nipple supplied with the kit reusing the
stock hardware.  This will serve as the fuel inlet.  Remove the stock plastic fuel rail inlet from the pulley (rear of van) side of the engine and install the supplied fuel pressure regulator in it's place reusing the stock hardware. Be sure that the hose barb is pointed down, towards the injectors.  This will serve as the return fuel output.

Be sure to protect the fuel lines from chafing using the provided split loom.  Choose a routing path that will avoid kinking and chafing points as well as any sources of high
radiant heat.  Use cable ties to reduce movement of fuel lines.