I was going through some info recently and saw that another thread on this had lost all it's pics, must have been held off site. Anyway I had done this mod myself and wrote it up in my build thread but I appreciate not everyone with a DI will look there for info and it won't show up in a search on Throttle Body mods, the pics are still around so I'll start a new one and get them out there. I won't go back to the original mod which was just disable and remove butterfly, I'll take it from the second stage I did later to a spare Throttle Body (TB) I had.
Hope this helps someone.
Carefully removed the butterfly shaft in its entirety. The idea is to have it look stock std on the outside, so I won't be cutting anything off externally. I used a long centre punch on the shoulder of the butterfly cutaway to knock the shaft, bearing and seal out of the body, then cut the shaft at the shoulder.
![524869]( "524869")
This is what it looks like, I used a long centre punch instead of a pin punch because it is a bit awkward to get at I didn't want a pin punch accidently slipping and possibly damaging the body.
![524879]( "524879")
I then wanted to remove the casting 'bubble' that covers the internal bushing for the old shaft. A good fresh cutter works wonders
![524871]( "524871")
Using a pin punch this time I gently tapped out the bushing to remove any chance of it falling out unexpectedly
.
![524872]( "524872")
Tight fit, but was just able to get my die grinder past the main butterfly to blend in the step where the housing has been machined for the butterfly, I didn't really want to remove that so had a go at in situ and it can be done even with an old die grinder. The step is about 2mm so I thought while I'm at it why not?
![524873]( "524873")
Tricky but came up OK, I was also able to remove a small amount of metal close to the centre of the divider wall.
![524874]( "524874")
As some would know I have a Water Meth injection point in my throttle body so I had to drill and tap 1/4" NPTinto my chosen position.
![524875]( "524875")
Did a thorough clean of the unit then refitted butt shaft, bearing and seal, used a pin punch to tap in the bearing then the seal.
![524876]( "524876")
The matching of the gasket to the TB is almost perfect. Gasket to manifold sees a minor difference, a little less than the shoulder I removed inside the TB.
![524877]( "524877")
All connections made, no outward signs of any mod except for the WM nozzle.
![524878]( "524878")
Hope this helps someone.
Carefully removed the butterfly shaft in its entirety. The idea is to have it look stock std on the outside, so I won't be cutting anything off externally. I used a long centre punch on the shoulder of the butterfly cutaway to knock the shaft, bearing and seal out of the body, then cut the shaft at the shoulder.
This is what it looks like, I used a long centre punch instead of a pin punch because it is a bit awkward to get at I didn't want a pin punch accidently slipping and possibly damaging the body.
I then wanted to remove the casting 'bubble' that covers the internal bushing for the old shaft. A good fresh cutter works wonders
Using a pin punch this time I gently tapped out the bushing to remove any chance of it falling out unexpectedly
.Tight fit, but was just able to get my die grinder past the main butterfly to blend in the step where the housing has been machined for the butterfly, I didn't really want to remove that so had a go at in situ and it can be done even with an old die grinder. The step is about 2mm so I thought while I'm at it why not?
Tricky but came up OK, I was also able to remove a small amount of metal close to the centre of the divider wall.
As some would know I have a Water Meth injection point in my throttle body so I had to drill and tap 1/4" NPTinto my chosen position.
Did a thorough clean of the unit then refitted butt shaft, bearing and seal, used a pin punch to tap in the bearing then the seal.
The matching of the gasket to the TB is almost perfect. Gasket to manifold sees a minor difference, a little less than the shoulder I removed inside the TB.
All connections made, no outward signs of any mod except for the WM nozzle.
