Originally Posted by willwren
Series 1 SC is the easiest. The L27 is kindof a bitch. Going strictly from memory:
Before starting (especially on the L27 or L36) put a small amount of penetrating oil on the nuts/studs holding the TB onto the SC/upper intake.
Disconnect the TPS and MAF connectors. Remove the MAF sensor, and place it on the dash of the car to keep it safe. Remove the intake plenum hose from the airbox/intake.
Remove the retainer clips from the 2 throttle cables (throttle/cruise). Place these on the strut tower or in your pocket, and mark which cable was top or bottom. Using pliers, release the cable guides from the bracket.
Remove the screw(*) from the bracket to the TB. Put this (these) with the cable clips, or put them back into the TB.
Now you get nasty. The crossover pipe heat shield needs to come off with the TB bracket. There are studs and nuts on the rear head. Remember the sequence you took them off. Draw a diagram. From memory, I THINK it goes Head/Nut/Bracket/Nut/heat shield/nut. On the L27, but not on the L67, there'* also a nasty little nut you have to remove that hides on the lower intake. After the bracket is removed, remove the 3 nuts from the TB studs. Make sure the anchors in the plastic upper intake (if equipped) don't spin as you break these loose. The studs may come out with the nuts, no problem. Remove the MAF screen carefully.
At this point, you can remove the TB. Use an intake-safe cleaner ONLY. An old toothbrush, or one belonging to an ex-girlfriend helps alot. Use the whole can. Let it soak, scrub, rinse, repeat.
For installation, install a new TB gasket (if needed), and reverse the steps above. Install the MAF sensor last, to give the cleaner time to evap before it gets exposed to it. Follow the Torque specs in Techinfo AT LEAST for the TB nuts/studs on the L27 and L36. This is critical on the non-supercharged cars.
Post count +1. That'* alot of brain work for only one.