How To: DIY TGV Deletes

[Jasper]

i ALWAYS see people posting up about these, asking every question imaginable.

*edit, sorry for crappy pics. they get the point across, but this camera sucks.


(please, if you quote me, dont quote my WHOLE post, as i dont know how much bandwidth photobucket is actually gonna give me. if someone can host these for me, lemme know)

well, this thread isnt for that. i'm not going to go into the details about how they affect idle, performance, are they worthwhile (imo, yes), or any TECHNICAL data. all i'm going for here, is to show you HOW to do it.

tools you will need:
large air compressor (i use a 26gallon / 8.4SCFM @ 90psi, and running my die grinder continuously @ 50psi, i'd have to stop periodically to let the compressor catch up)

pneumatic die grinder (i use the $15 Husky h*me d***t special, worked great for almost 2 years now, and countless sets of TGVs, manifolds, turbos, etc etc)

carbide burrs (not NEEDED, as this is aluminum, but makes life 100x easier). i did MOST of the work with a single-cut tree-shaped bit. a double-cut or aluminum specific burr would be better (less galling)

can of WD40 (or your preferred cheapo lubricant. WD40 is cheap, and works great, and i had a spare can of it)

flapper wheels: i use 1"x1" 60grit and 80grit. you CAN use 120grit if you REALLY want, but its not necessary). plan on using at LEAST one whole 60grit and one whole 80grit wheel. i DO have a homemade porting tool that cuts down on this, but thats another thread.

time: this will take you a solid 2-3 hours to do correctly.

disclaimer: not my fault if you screw up, blah blah, removing emissions equipment is illegal, blah blah, etc etc, this is a guide only intended for professionals, etc etc.

note: you will have to find your own way of sealing up the holes. you can use a tap, brass plug and JB weld, or you can weld the holes shut (its cast aluminum), use alumaloy *TMS has had great luck with this*, or simply reinsert the rod to avoid that dreaded CEL. if you want more details on these methods, PM me, or SEARCH.




step 1: remove your intake manifold (leaving the TGVs on during this process makes its easier). not gonna explain this one. if you cant remove the manifold, DIY TGV deletes may not be for you.

step 2: remove TGVs from manifold. set one in a vice, as you dont want things jumping around on you.

step 3: remove the stepper motor and sensor. (i suggest sensor first, just because it is rather delicate, you'll need a SMALL phillips head screwdriver for this, and probably some PB Blaster). to remove the stepper motor, it's an 8mm or 10mm (can't recall)

(sensor, removed)


(stepper motor, removed)




step 4: you need to remove the screws holding the flappers in place. this can be tricky. it's IMPOSSIBLE to simply unscrew them. they are peened over at the factory to prevent them from falling out and being ingested into the motor (a la, Nissan Sentra style). you'll need to grind the back of the screws off before you can attempt to do this.

(before)


(after)


now, you MIGHT not be able to actually remove the screws. if thats the case (or you strip it), a 5/32nd's drill bit is nearly the EXACT same size as the screw (just a hair larger), and is perfect to drill them out (in which case, grinding isnt needed).

final goal:



you can now remove the flappers.

now, its time to remove the rod.