How to free up air flow through the TGVs. - Subaru WRX Forum
 
LinkBack Thread Tools Display Modes
post #1 of 1 Old 01-29-2008, 10:50 PM Thread Starter
WRXpert
 
LiL Shoaf's Avatar
 
Join Date: Jun 2005
Location: Pennsylvania
Posts: 1,810
Images: 2
LiL Shoaf is more helpful than not
Send a message via AIM to LiL Shoaf Send a message via Yahoo to LiL Shoaf
Post How to free up air flow through the TGVs.

OK, so you want better flow through your TGVs but don’t want to drop the cash to have it professionally Ported and Polished or to buy the APS units.. Well, do it yourself and save some cash while making more power..

Ok. So it’s really very simple but very time consuming. Follow the service manual for your model to remove the intake manifold and TGVs. Keep in mind that when you remove your Fuel Injectors ALWAYS install new seals when reinstalling the injectors.

There are a few ways to clean up the air flow through the TGVs.

- Remove the “Flappers”
- Remove the “Flappers, Rod, and Motors”
- Remove all hardware and port and polish the TGV body.

Ok. So if you’re just going to remove the “Flappers” things are a lot easier.. Once you have the TGVs removed from the car hold the flappers open (so there will be no need to pretension the motors) and use a carbide cutter on a die grinder to grind off the part of the small screws that stick out the underside of the rod. They mushroom the end of the screw so they can’t back out over time and fall into the motor. If you try to remove the screw with out doing this you WILL round it out and have more problems.. Once the back of the screw is ground off use a P2 (#2 Phillips) screwdriver to remove the screws. Take care to not round off the screws.. Apply plenty of pressure to ensure that you will not slip when trying to rotate the screw.. The screws are soft and round easily.. If this is as far as you feel comfortable doing then reassemble as per your service manual. Remember to install new gaskets and seals..

However if you are comfortable going further then go for it.. Once you have the TGVs removed from the car remove the motors from both sides. Next hold the flappers and use a carbide cutter on a die grinder to grind off the part of the small screws that stick out the underside of the rod. They mushroom the end of the screw so they can’t back out over time and fall into the motor. If you try to remove the screw with out doing this you WILL round it out and have more problems.. Once the back of the screw is ground off use a P2 (#2 Phillips) screwdriver to remove the screws. Take care to not round off the screws.. Apply plenty of pressure to ensure that you will not slip when trying to rotate the screw.. The screws are soft and round easily. Once both flappers are removed from each TGV body tap on the rod that extends out the side of the TGV body opposite the spring and gear until the rod comes out. If this is as far as you want to go then put the motors back on or find another way to seal the holes. Reassemble as per your service manual. Remember to install new gaskets and seals.. This can only be done if you can eliminate the CEL via your engine management system.

Now if you are able to go all the way get to it.. Once you have the TGVs removed from the car remove the motors from both sides. Next hold the flappers and use a carbide cutter on a die grinder to grind off the part of the small screws that stick out the underside of the rod. They mushroom the end of the screw so they can’t back out over time and fall into the motor. If you try to remove the screw with out doing this you WILL round it out and have more problems.. Once the back of the screw is ground off use a P2 (#2 Phillips) screwdriver to remove the screws. Take care to not round off the screws.. Apply plenty of pressure to ensure that you will not slip when trying to rotate the screw.. The screws are soft and round easily. Once both flappers are removed from each TGV body tap on the rod that extends out the side of the TGV body opposite the spring and gear until the rod comes out. Now with what ever means accessible to you remove the splitter. Next I used a grinding stone to work out all the uneven spots and “rough in the opening”. After that was done I used small flap wheels of 60 grit sand paper to smooth it all out. I started out with the smallest sized wheel and worked up to the largest wheel that would fit to ensure the smoothest final product.. It’s always a good idea to keep an old gasket from your tear down so you can “Gasket match” your Porting job. To do this simply taper the first ½” or so of the opening (Intake Manifold side) so that you can’t see any of the TGV body inside the opening of the gasket when you lay it in place. This will prevent turbulence at the union of the TGV and Intake Manifold. Reassemble as per your service manual. Remember to install new gaskets and seals.. This can only be done if you can eliminate the CEL via your engine management system.

Pictures to come as soon as I find my cables for my camera.

02 WRX.. "It's fun when it runs.. Problem is that it hardly ever does..."
LiL Shoaf is offline  
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are Off
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On