It would seem to agree with my assumptions earlier about the PCM fully closing the IAC when you turn the car off. Adjustment may not be necessary but correction of a mis-adjusted install may be

Are you saying I butchered the install :?: :?:

I would think that the 28mm dimention is the depth of the IAC cavity. So basically, as long as it'* less than 28mm, it is ready to install. Or you eluding to an improperly seated O ring or other problem.

Well I did notice that the o-ring was a little too easy to pull off on mine...Maybe pulling it, fully extending it, and double checking the o-ring is in order ?

OK. I'll do that. One last thing. Is the TB "butterfly" supposed to be totally closed or damn near totally closed at idle? If I recall correctly, there was a small gap after it was cleaned.

Thanks for the input BTW

Well I didn't notice any gap in mine at all..I'm sure since there is no REAL seal there there'* some air getting by...I'd say close it as much as possible, the IAC is capable of opening pretty far to adjust.

Oh hey while you're at it you may get a "free mod"..I noticed when reinstalling my TB that the gasket hung over on the bottom. I took a knife to it and probably grabbed 1-2mm. Doesn't sound like a lot but it doesn't take much. Check it out