Not sure if this has been covered before, but I figured I'd look at what improvements could be made to the stock 2.5L throttle body. The stock unit is pretty precise for a mass produced item but the fit & finish of the individual parts can be improved once taken apart. Areas I found for improvement are shown below:
1) The screw heads can be flattened and rounded to a smooth edge.
2) The screws length was trimmed so that they didn't hang out past the shaft and the shaft was filed flat on the half-round side.
2) The brass butterfly was thinned to about 1/2 it's original thickness.
This is totally free mod and although it's not real scientific, the butt-dyno tells me this was totally worth the 2 hours + 1 six pack to do it. A noticable improvement in the ability of the engine to gulp air. The secondary opening is more pronounced and the RPMs build quicker and quicker as the RPMs climb to red line. Tomorrow: Optimization Stage II. (I'm on vacation, and it beats the heck out of yard work! :D)
