VR6 Throttle Body Swap

From THE Corrado Forum Knowledge Base

(See thread in group-buy section in forum for info on buying a big-bore TB)

Special Tools needed

• 6mm Allen socket
• 8mm Spline Socket/key

Optional parts

• New Jubilee clips
• New TB Gasket (021 133 073C)

Procedure

• Depressurise cooling system by undoing expansion tank cap (very slowly with a cloth if the engine is warm!)
• Remove plastic engine cover.
• Remove plug leads from the top cable guide (or off the plugs if you have the correct tool)
• Remove the 2 spline bolts and move the guide forward and lift up to gain access
• Unplug the MAF, TPS and the cable going into the blank socket (on UK Corrado’s) on the flexy pipe from the MAF to the TB and move wiring out of the way…
• Remove the heat shield from the TB (late models only)
• Undo the flexi pipe at both ends and from the ISV and Cam cover (you may need new Jubilee clips to replace these ones depending on how they were removed) and lift out of way (be careful with the newer type plastic pipes as they are not as flexible as the older ones!)
• Pull up the throttle spring and unclip the cable
• Remove the 4 allen bolts holting the TB on, make sure the socket is in fully to reduce the risk of ‘rounding’ – this will also require a mix of small extensions and maybe an allen key too as access is limited.
• Once the bolts are removed the TB should just drop, usually leaving the gasket in place if in good condition, if not then replace this.

• On an exchange TB you will need to swap over some parts, the ISV damper and the TPS if needed (both held on by 2 screws) – make sure the new unit is clean, the throttle butterfly is tight and that it opens freely!

• Refit is the reversal of the above making sure the throttle operates freely and all wiring is run correctly and jubilee clips etc are located and not obstructing the throttle operation.

All Done - Remember to plug the MAF back in and tighten the expansion tank cap!