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Wednesday, February 15, 2006 12:41:35 PM - Views


VintageWatercooleds.com Technotes :: ATS Technote - Bigger throttle body

This mod shows how to port match and install one of the larger throttle bodies on an A1 car. You can get an A2 throttle body, A Fox throttle body or one from an Audi 5000 - which is what is shown here...

First view of the Audi 5000 throttle body I got at a parts guy, yuuuuky!, but hidden under all that gunk is a perfectly good throttle body, once cleaned and greased properly, will work wonders
another view of same TB
bottom plane , nice eh? yeah 3.5 hours later, after taking it completely apart (pay attention to the springs and the way they mount... hehehe.
Same throttle body, all cleaned up and ready for the transplant
another view of the cleaned up TB
and see how shinny it is ?
here I indicate, (clockwise from left to right), the throttle switch wires to be removed , the clip for the gas cable, and the 2 clamps that need to be slackened.
next the vacuum line that reached behind the throttle body to be disconnected.
(left to right clockwise) the vacuum line, and the two clamps to remove the vacuum booster out of the way for the surgery to happen.
Most people use Allen keys, I use Allen sockets, why.. easier (power of a ratchet handle to "pop" them bolts off careful not to strip the bolt in place.. they can be HARD to come out. if need be use pry bar or pipe to give you more Humph .
Left we see the standard Scirocco 8v throttle body with 15 years of usage, never been cleaned... and right the cleaned up Audi 5000 throttle body, 2 things to move, the bracket (2 screws) with the throttle switch atop it, and the gas nipple that will need to be atop the new throttle body. (11mm nut)
Now that we have the throttle body ready to go... lets enlarge the intake to permit efficient air flow from the throttle body to the engine. First , using 2 bolts place flat the gasket against the body of the intake manifold and using a permanent marker, trace the new inside line of the gasket area.
STUFF THE INTAKE, count your rags, I did the grinding directly on the engine, it is not easy and will make a mess of aluminum shreds all over the place, the rag prevent any of it falling into the intake and end up into your engine later...(yes this is bad if it does.)
Tip from G60synchro: When you put rags in the intake to port the inlet, You can also coat the surrounding area with grease to catch any loose debris. When you're done, wipe it clean along with all the shavings!!
once you are done grinding, DON'T TAKE THE RAGS OUT!, Vacuum the whole area, get everything you can remove one rage and vacuum again, the metal bits are most defiantly bad for engine.
Here we see once everything is vacuumed and dug out
Bolt the Throttle body back on with the gasket, nice and snug.
Install the gas cable back on assembly, the blue arrow is to indicate a gap on the small throttle plate this is NOT good, you need to adjust your cable.. or car will start idling 2000-3000 RPM at the turn of key.
the blue arrow indicated the clip that you pull out, give the slack to the adjustable cable and check in the throttle body that the flap is closed, clip it in position, your are done for this bit.
on the Audi 5000 TB I got I had 2 nipple vacuum lines that we unused (my Rocco only required 1), so I devised using clear plastic tubing, heat the tip up, squish it closed, suck on other end to make sure the end is closed and slip it on..
here I show the resulting "plug" I made. works..

I had to purchase a bigger 5/8" plug for the air intake, as mine already was through the rubber housing and 2 would of been bad. I clamped it down and reassembled everything up.

turn the key.... if you did not forget a rag in the intake manifold, it w3ill start just fine. adjust your idle and your done....go enjoy a ride....

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