fiestaturbo.com

[jayrs]

Guide to modifying a 2 litre mondeo throttle body

Tools needed

Torx bits
Pliers
Hack saw / junior hack saw
Pencil or marker of some form
8mm spanner/socket
10mm spanner/socket
9.5mm drill bit
10-10.5mm drill bit
Drill
Scraper
3.5mm drill bit
4mm tap


Parts needed

1.6/1.8 zetec throttle body for parts
Cleaner
Spacer washers with hole size no smaller then 9mm
Screw
Brillo pad
Carb cleaner/petrol

right there’s a few ways a couple of bits can be done so the need for say, the 4mm tap, 3.5mm drill and the screw wouldn’t be needed, but ill do this guide how ive done mine and you will see where you can do things a bit different.

First up, if you’re worried about how it goes back together take some pic’s, or use these as ref.

Strip the 1.6 throttle body down, all you want is the linkage off the side and the TPS (throttle position sensor)

Now strip the mondeo one, while it’s apart you may as well clean it, if you don’t want to skip this part of the guide.

To clean the throttle body, remove all linkage on the side, that’s 2 10mm nyloc nuts.
Remove the TPS from the other side using the Torx bits.
Now remove the Torx screws that hold the butterfly plate in place.
Open the throttle body and pull the butter fly plate out from the back, once this is done the shaft can then be pulled through from the right hand side (when you look face on to the throttle body from the front).
If the butterfly plate is caked in crap use the scraper to clean it off and use a brillow pad to clean the rest, the use of carb cleaner etc will more than likely be needed, but petrol etc could also be used
Do the same on the shaft and also clean the inside of the throttle body out also.
If the out side of the throttle body is mucky clean it off also, pref this should have been done before starting to strip it.

Anyway now let’s say everything is clean and dry.

Pop the butterfly plate shaft back in, put the plate back in from the rear and screw it back on.
At this stage you can put the 1.6 TPS on if you want or wait till later, but I put it on at this stage to give the throttle a bit of spring to keep the butterfly plate shut.

I wrapped the throttle body in a rag at this point to cut a couple of bits off, note though, I put the shaft back on and the TPS etc to stop any swarf from the cutting getting into the bearings.

There is a lug on the side which gets in the way and can be removed flush or close to the body.




Right, the 1.6 main linkage will not fit on the rod on the 2 litre throttle body as the rod is bigger, and although I hate this crude way of making it fit its really the only way out of it.
You have to drill the hole in the plastic bigger.
The hole is tapered so make sure you hold the drill straight, drill through from the bigger side in with no more than a 9.5mm drill bit, or do smaller then ream it out, but the shaft is 9mm and you don’t want it tight.
Your also see the base of the shaft is bigger, that’s 10mm, so the end of the plastic in the main linkage needs opening out, I used a 10mm drill bit and it was a bit tight but I didn’t have a 10.5mm drill bit to hand so wiggled the drill about a bit ( I hated doing it but had no choice) but remember, you only need to go in about 10mm so don’t drill it right through of that linkage is fcuked!

Clean out any burred over plastic from inside and grease it a tad, once it fits nice and moves freely move on to the next stage

This next bit you will have to rough assemble linkage on the throttle body to see where you have to cut etc, note, you do not have to fit the springs, this part is just testing etc.
your see in my pictures I cut the whole bit off and put my own stop in, this was easier for me than bothering to cut and shape the lug to make a stop out of what was there, if you choose to shape a stop out of the lug then so be it, your have to mark it and cut it and shape it till its right and your happy with it, but as I didn’t do that im not going to go into any details about it.

Right, with this lug removed and the linkage all fitted on open the throttle to its widest point, you see that the butterfly plate goes to full open and then some more, so in turn trying to shut it self but doing a full rotation, which isn’t what you want, so hold it at its most open position and mark on the side (where the lug was cut off) where the stop has to be.
Remove the linkage again and if like me you plan to drill it and tap it and fit a screw then do so but please note, you must make sure the edge of the screw is next to the line you marks as stop, and not the centre of the score other wise you wont get full open throttle.





Right, mark the hole, approx 2 mm away from the line you marked as stop (adjust this for the size of screw you plan to use, I used 4mm) and drill it deep enough to tap for the length of the screw, try not to break through into the inner part of the throttle body as its not needed.
Once drilled, tap it out and fit the screw and check its right, if it’s come over and the throttle isn’t getting full open you can file a bit off the screw or the linkage but a tiny bit won’t make a difference.



With all this done, I put a bit of grease on the shaft for the main linkage and reassembled it.

To reassemble it you must fit the linkage on the butterfly plate shaft, remember to load the spring to give tension, once fitted remove the small roller at the other end of it







Now fit the main linkage, it’s a bit fiddly but it will go, and again remember to load the springs to give tension.

Now fit the spacer washer and the 10mm nut and tighten, depending on the size of your washer etc you have to slacken it a tad to allow free movement.



Now refit the roller on the first part of the linkage and check it work as it should.

Now at this point, or even earlier if you wanted you can adjust the stop, if you look at the top there’s a small threaded bit that comes out to stop the linkage shutting too much, the butterfly plate will only shut so far so call that fully shut and adjust the stop to suit, but you cannot adjust the threaded part, you must bend the stop part on the linkage to touch the threaded part, this can be done by opening it and getting pliers in there and just tweaking it, it don’t need to be hung on just tweaked, as said you might want to do that when its all in bits as I did, but I found (as the springs were now on pulling it all tight) it had been adjusted a bit too much so I had to bend it back a bit..



Right now the throttle cable bracket is not a direct replacement fit on the 2 litre throttle body, you need to trim some of the bottom to fit it.
I would of like to off cut the end off mine and made a new end for it so it fitted just as I wanted it too but I didn’t as not everyone could do this so I done it in a way that anyone could.
Your have to fit it and mark it to see where needed cutting etc your self but the picture below shows what I done, even if I did cut a tad to much off but its held on with the main bolt at the top and this one at the bottom with the washer will hold it on fine.





ive done this for my 2 litre engine tham im putting in my xr2, im using a rs1800 inlet manifold.
if you use the same manifold and can get the rs1800 throttle body then use that, if like me you dont have one, then as above, the 2 litre mondeo one can be used.
please note, you cannot use the metal gasket when refitting, you must use the paper one to allow air flow via the hole behind, unless you cut the metal one.

[black2]

Dam the pictures have stopped working. Im ready to convert mine now.

Gareth.

[jayrs]

hmm, dunno why that is, ill see what i can do

[jayrs]

pictures up and running thanks to capri sorting it for me, some code was switched off.

[black2]

Nice one jay

[jayrs]

hope it useful for ya mate

[jordan2litre]

just bumping this as i want it to hand for doing it myself , looks quite complicated , is there any benefit having the 2 litre mondeo one over the rs1800 ?

[MB7201]

No, the rs1800 one is the same size.

[jayrs]

as above, if you can use a rs1800 one go for it mate, if not the mondeo one being modded is the next best thing.

i only done it as i got the inlet off ebay and it was bare, and as i bought a complete mondo for £30 ages ago mind, i just used the throttle body and some bits for a spare 1.6 escort (zetec) one i had

[jordan2litre]

"as above, if you can use a rs1800 one go for it mate, if not the mondeo one being modded is the next best thing."

ive found a RS1800 throttle body online somewhere but will the mondeo one give more performance ( i know probably not and ridiculosly marginal if so ) but if it does and indeed has a bigger port etc then i will buy a 2 litre one , any ideas ??

or should i just get the RS one as there internally the same ?

[Smo]

If you can get an RS1800 one, just use that. The Mondeo one offers nothing over it, apart from usually being cheaper!

[Fi3staz]

Sounds complicated but that's a nice info you have there.