here is a stock truck intake and the TBSS intake side by side...the first mod you need to make is to the fuel rail crossover...notice the bend on the passenger side of the intake prevents the fuel rails from sitting all the way down
well the way to solve this was to take the crossover off...really simple to do just unscrew the star head that holds it in the rail and it pops right out. I then took it to my buddy Taylor over at Dallas Performance and he suggested we weld a -6an fitting on it and put a steel braided line insted of the metal crossover and in doing this it would allow better flow to the other rail as well. So within a matter of 30 minutes he had it cut and welded for me and i was on my way
So now the rails were able to sit all the way down. For the new crossover line i just went to Performance Auto Supply and grabbed a 14" -6an line and it fit great nice and tight. So the next problem was the space between the fuel rail tabs and where they bolt up to on the intake...there is about 3/4" of difference and they dont line up directly. So to fix the i just drilled the plastic tabs for the new holes and used some spacers along with a couple of washers and also had to get longer screws...believe they were 40mm, just picked them up at O'Reilys Auto Parts
The next thing i had to decide is to run the 90mm throttle body or get the adapter plate and keep the 78mm stock one. Well i couldnt justify another $300 for a new 2 stage plate and the $215 wiring harness from Rush Perfomance because the 90mm has a different 6 pin plug and the 78mm has a 8 pin plug. So i choose the 78mm with the adapter plate, it bolts up rather easy to the TBSS manifold.
In the pic you can see how it bolts up...throttle body...nitrous plate..then adapter plate...pay no attention to the wiring i didnt have a chance to loom it up yet
The main problem i came across was the EVAP purge solenoid, the TBSS one sits inline and not in the intake like the trucks do, this is solved either by getting one from the TBSS or off an LS1 camaro, the plugs doesnt change. I choose to just cap it off and remove the code off the tune, some may not have that convienance or want to do that.
If you have a fuel pressure regulator like on the 99-03 trucks all you need to do it get you some 1/4" vaccum line and there is a capped vaccum port on the passanger side of the intake, you break the nipple off with a pair of pliers and that problem is solved.
All in all this looked harder then it turned out to be and this swap can be done in a matter of and hour or 2, i found it best to find someone that has a crossover laying around and have it modded before you start the swap.
Any questions please ask.
Edited by mean05, 09 June 2008 - 09:37 AM.