You definitley want to do the throttle body rework. It is perhaps one of the best things you can do for the engine smoothness. I too, noticed the slight feeling of power pulses at lower rpm's. After doing the rework, they are all but gone. The smoothness of the engine is increased quite a bit.

I did the rework last week ina about two hours or so. First, you need to remove the transion casting by loosening the hose clamp and the two bolts at the throttle body. Also, don't forget to remove the connector from the sensor on the casting. Then be sure to cover up the openings left over. I used ziplock bags with a rubber-band around them to hold them in place.

Next, I removed the sensor from the casting using a wrench. I did this so it would not get coated in aluminum dust as I sanded the part.

On the part you will notice that the small end, where the air enters the casting, has the squared/stepped surface that needs to be smoothed. I accomplished this with, forgive me but for some reason I can't remember the proper name, something like a drum sander, but with flaps of sandpaper instead. I used 120 grit, which used in a drill at full speed, worked quite fast. I sanded out the first inch or so into the casting, just smoothing it out. But, the real work is to bevel the leading edge so that the air has a smoother transition into the casting. I took the leading edge down to almost a knife edge. I stayed at about a 30 degree angle since the casting is not so thick here(where the hose fits over).

When finished sanding, I cleaned it out the casting with hot water and wiped it out real good. After this, I reinstalled the sensor and the casting back onto the car. I then took the car out for a drive and enjoyed a MUCH smoother power delivery, and what feels like a bit more torque, also.

I am sorry I cannot provide pictures, as I lack a digital camera. Perhaps Dean can repost his. Or you can check the archives. I remember them from a month or two ago.

I hope this was a helpfull post for you.

Eric Burr
Ramstein AB, Germany
99 9-3 33k miles

• Dean, TG...question, Richard P., Wed, 25 Oct 2000 16:28:04
  • Re: Dean, TG...question, KeithG, Tue, 31 Oct 2000 16:21:13
  • Re: Dean, TG...question, Dean, Thu, 26 Oct 2000 09:54:43
    • Have you posted pictures of this before???, Richard P., Thu, 26 Oct 2000 10:24:58
      • Re: Have you posted pictures of this before???, Dean, Thu, 26 Oct 2000 17:32:52
      • Link to Throttle body transistion casting pictures..., REM in Seattle , Thu, 26 Oct 2000 15:39:52
        • Throttle body transition casting rework info....(long), REM in Seattle , Thu, 26 Oct 2000 17:45:38
      • Do the casting rework, it is really easy. (long), Eric Burr, Thu, 26 Oct 2000 15:22:14 <-- Viewing This Message
  • Re: Dean, TG...question, TG, Thu, 26 Oct 2000 09:50:57
    • Do you by any chance know, George D, Thu, 26 Oct 2000 10:40:32
      • Re: Do you by any chance know, Dean, Thu, 26 Oct 2000 17:22:28
        • previously posted boost numbers, from the manual, MJM , Fri, 27 Oct 2000 08:57:14
        • Thanks Dean, that's good to know n/m, George D, Fri, 27 Oct 2000 07:44:03
    • Could be, but it really feels like power..., Richard P., Thu, 26 Oct 2000 10:26:22

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