How to: Port and Polish: (TB and Manifold)

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How to: Port and Polish: (TB and Manifold)

Post by CateraMV6 on 3/4/2010, 18:25

This thread is going to cover how to free up some free HP from your engine.
These engines are produced in mass quanitites, and often the attention to detail is... confused not that great.
To my surprise the build quality of our engine the X30XE is quite good, and everything fits perfectly but there is always room for some more.

The parts I got are Y32SE Throttle body, and Intake manifold, combined with 3.2L Fuel injectors.
The throttle body has around 50K miles on it and as you can tell the EGR system sure got it dirty!




Each of the throttle plates, as you can see there is quite a bit of room to remove material from the center bar and free up some flow.




Here is the 1st stage of porting, I took 150grit sand paper, and a dremmel and sanded off the edge found inside the throttle body, I also opened up the front part so now its a smooth bore all the way to the narrowest part.




Next up, I need to clean both TB openings and move to a 600grit for a finer finish, and then finish it off with 1000grit.


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Re: How to: Port and Polish: (TB and Manifold)

Post by Matera97 on 3/5/2010, 15:19

These changes seem to be quite minimal. How much extra HP is this mod expected to gain?
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Re: How to: Port and Polish: (TB and Manifold)

Post by CateraMV6 on 3/5/2010, 16:06

Omega 2.5 & 3.0 V6 - Performance Throttle Body
Optimum fuel economy when wanted - Optimum horsepower when needed.

This throttle body has been modified to allow more air to move faster into your engine. Fitting this throttle body:

Increases engine horsepower (BHP)
Improves engine torque and vehicle acceleration
Improves throttle response
Helps remove hesitation & flat spots

Fitting it is a simple job for any mechanic or hobbyist and typically takes no longer than 30-60 minutes. The throttle body has been worked (where possible) to the following specification:

All internal casting & pitting marks removed and smoothed out
Internals re-profiled for more effective gasflow
Internals highly polished for faster gasflow
Inlet lip 'bell-mouthed' to allow faster gasflow
Obstructive inlet bore step smoothed out for more effective gasflow
Cleaned, lubricated & re-assembled with low profile screws
Warranted against throttle spindle breakage*

More information on gasflowed throttle bodies, engine tuning, cylinder heads & inlet manifolds can be found at this website.

*Throttle spindle breakage frequently occurs when the spindle is 'halfed' to improve performance. This causes extensive engine damage and an expensive repair bill.

Q. Will this fit my car/engine?
A. Maybe - Please check by matching it by sight with your existing throttle body prior to purchase. The item title is only a guide and the throttle body will only fit some models. Please ask a mechanic to help you if you are unsure about whether the part will fit your engine.

Q. This does not fit my engine. Can you supply one that does fit?
A. Yes - You are welcome to send us your throttle body to work. You can send your existing unit or source one from either eBay or your local scrapyard. All work undertaken must be carried out though eBay as per eBay policy.
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Re: How to: Port and Polish: (TB and Manifold)

Post by CateraMV6 on 3/6/2010, 20:02

:::FINISHED:::

1. Installation.
You need 7mm and 8mm sockets. 1 wratchet, and a screw driver. 1 pair of needle nose pliers.

First you need to loosen the hose clamps from the rubber connectors between the Multiram and the TB, both are 7mm bolts... Also disconnect the power connector to the TB.
Second rotate the trumpets around to gain some room around the TB.
Third, remove the 4 bolts holding the TB with the 8mm socket, they are star shaped but the socket works jsut fine.
Fourth, remove the two water hoses form the TB and spaw them on to the new TB.
Fifth, remove the vacuum line from the TB and swap it to the new TB.
Sixth, reinstall the new TB. Reconnect the electrical connector.
Reinstall all the rubber hoses and tighten all bolts and lines.
Finally turn the ignition on for 5min, the TB will cycle to off-WOT-off and recalibrate itself.

Once that is done Ignition off, then ignition on, wait 3sec for the fuel pump and start your car, you should see 500rpm once the engine is warmed up.
Upon start up mine ran at 1100rpm until it got warm, so thats about 100rpm more then stock..
Once it warmed up it was fine though.

2. Test drive.

I got the car warmed up to 190deg and took it for a spin before and after the install. My first impressions are drives like before, no issues, no hesitations, the fun part is when you git the high notes of the engine, somewhere north of 3500rpm there was a slight dead spot before the multi ram kicked in at 4000rpm, now with the new TB its a very smooth transition so I am certain that the car gained some power in that area.

Then the spring from 4000-6600rpm is just a blast, its stabbing power and very smooth and predictable output, and thats where the new TB job really shines. To my surprise a fella with another silver Catera driving down one of the main roads, I rolled up next to him, gave him the thumbs up and he took off,, of course i followed him and messed around a bit, to my surprise I was pulling on him gaining 1/2 a car from 4000-6000rpm in 2nd gear, from a dead even roll... so you can imagine the TB and exhaust have a lot to do with the extra bit of power.

All and all it was well worth the trouble. The TB took maybe 2hrs all together to port it with 60grit paper on a dremmel, then 150, 300, 400, 800, and 1000 by hand. entire job can be done in less then 4hrs...
As far as power increase well its not much to feel it but it maybe good for 1-3hp... < FREE
With the ported manifold, and new fuel injectors and FPR, i am expecting more like 5hp... Last dyno showed 194-195RWHP, so if next time I get 200, I will be quite happy.


3. Install Photos.








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Re: How to: Port and Polish: (TB and Manifold)

Post by yomincarr on 3/7/2010, 22:20

good work guys, as soon as i can raid the junkyard ill give it a try :-)
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Re: How to: Port and Polish: (TB and Manifold)

Post by CateraMV6 on 3/8/2010, 23:04

Stage 2

This part requires removing of the plenum and the lower intake runners.

Once you remove the two bits, you mate them and you flip them over.

Take a look down through the ports and you will see the plenum is not exactly centered on the intake runners, so at this point you can shave some material off the plenum to even out the step.

Te less steps you have the smoother your flow will be.













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