Throttle body upgrade-Judgemobile

[JUDGENINJA]

INGREDIENTS

1. 1 x Volvo 900 series 3.0ltr 24V throttle body
2. 3 x 76mm 90 degree bends
3. 1 x 76mm T-piece (or 6" pipe)
4. 1 x 76mm 8" pipe
5. 1 x "62ID x 76OD" spacer
6. 20mm self tapping insert (not pictured) optional
7. 6 x jubilee clips

Tools

1. Screwdriver
2. Round file or small grinding drill accessory
3. 10mm socket/spanner
4. 13mm socket/spanner

Instructions

• Remove the inlet manifold and unbolt the existing throttle body from the manifold.
• Offer up the new Throttle body and you will notice that it is interfered with by the manifold casting. Using the file or a grinding tool small enough; widen the hole to suit the new throttle butterfly.
• Swap over the ball joint plate off the old thottle body onto the new one using a 13mm socket/spanner.
• Install the new throttle body to manifold and then refit manifold.
• Using the pipework re-create the piping system arrangement.
• Using a Sharp knife you will find that you need to cut plastic around the area of the intercooler to allow good clear connection. I also cut 30mm off one end of the 90deg bend to pull the pipe work straight along the front slam panel.
• Now you need to decide what to do with the Idle Control Valve attacted to your Vacuum tree. using the 15mm insert decide where you want to connect to and press through the side wall of the pipework and connect up the ICV as you wish....
• Now adjust the throttle to suit...

If it makes any difference I'll let you know when I've tested it at the next RWYB next year some time.....

[dougt5r]

How much bigger than stock the 960 TB is


(for the record it IS the same as the 850NA... so if you find the single plenum 850NA intake you can just use that)

[shaun850]

did you make the cold air box to fit a suitcase in?

[JUDGENINJA]

did you make the cold air box to fit a suitcase in?

Yep...yoo never know I might run out of space in the car for that last bit of shopping....

[JUDGENINJA]

How much bigger than stock the 960 TB is

(for the record it IS the same as the 850NA... so if you find the single plenum 850NA intake you can just use that)

I'm not sure what size the standard one is (although I could go out to the garage and measure it up), I had to use 76mm hosing to connect it up...