Throttle valve R&R, 1.7 liter et al Options

[r3dplanet]

So I decided to pull the throttle body (valve) from my car in order to rebuild it. The throttle valve had a tendency to leak and stick. It was also moderately dirty. At the time I was on a personal mission to pull and restore every major component of the D-Jet system. Since then, I've performed similar operations on the MPS, AAR, etc. Perhaps I'll document those operations in a similar way.

My car is a 1971, but the engine is a 1973. I know that other engines use a top-mounted throttle valve, but it's actually quite similar to the side-mounted units like mine.

I realize that this isn't superorbital propulsion engineering, but it might be helpful to somebody.

Here's the original setup. You can clearly see the part number 022 133 067 under the muck, along with various scratches and nasties.







In this photo you can see that there's quite a gap around the brass air valve and inner diameter of the main bore. It seals if the valve is fully closed, but even the smallest relief of the lever allows air to pass.

[r3dplanet]

It's super easy. I'm mechanically inclined but I'm no machinist.

Just be careful with the reamer. I initially brought my throttle valve to my machinist thinking he'd use some fancy bore or lathe tool to precisely drill out the shaft, but he worried that it would remove too much material as the aluminum is soft. So he just had me drill a precise hole and use a hand reamer. But I can see that it would be really easy to take too much material out. If that happened, then it's time to find a new unit.

Zonedoubt -

I love the seals you have on your TB. I've never seen them on a 1.7 liter TB, but that's not to say that there couldn't be. I'm not sure how they could be adapted given the different inset of the shaft, but would love to have a better seal. Bronze bushings are clunky, but better than nothing at all.