flyboy367
Mudrunner
Reged: 06/24/05
Posts: 477
Loc: new jersey
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well today i finally got to change my sparkplugs. i did the coils wires and bosch platnum 1's. i used the writeup at the top of this page. went beautifully. while i had the intake assembly apart i figured what the hell ill clean the throttlebody. so here is what you do.
parts:
big can of carb cleaner.
socks
toothbrush, preferably one you dont plan on using again.
no parts stores by me carry kia parts and the only kia dealer has limited so i used permatex form a gasket gray. i use the stuff assembling superchargers so for the kia it shouldnt be a problem.
tools:
12mm wrench
6mm? allen head tool.
step one, pull intake assembly apart as per instructions for changing plugs.
your motor should then look like this:
if you dont know what this is please do not go any further 
gently remove the 3 wires to the throttle linkage. just open the blades and remove the wires, you need to mess with them a bit but its nothing more then moving the cylender out of the slot. i couldnt get a good shot of it but youll know it when you see it. then take off the tps sensor connection. now 2 12mm nuts and 1 hex bolt are in your path. the hex bolt i forgot to write down the size. i think its a 6mm. it feels like its gonna strip but hang on it will come out. now just underneath you will see 2 hoses with squeeze clamps on them. pull them suckers off. its the coolant passage. many of us racers usually block them off but in this case its such a small area the coolant moves thru i figured just leave it be. now a little pry and that tb should come right off.
then you will see this:
if you look close on the left side there is the pcv. might as well change it now it will never be easier.
so here is a 100k mile throttlebody that has never been serviced.
pretty nasty huh. go ahead and soak that sucker in some carb cleaner. and get a drink.
srape off the gasket. use the toothbrush or even a dental pick to get the gunk off the throttleblades and on the tb where they hit. and scrub scrub scrub. you will feel the difference as you open the blades while you clean.
now it should look like this:
dont forget to clean up the intake and get down in there to get out the gunk. dont spray into it though otherwise youll get a surprise on startup from pooled cleaner in the piston chamber. i just spray on the sock and toothbrush and scrub away.
now you can go ahead and spread a thin layer of the gray stuff and reinstall it all. or look below.
part 2 not for the faint of hart.
i looked at the intake tube to the throttlebody and noticed how much material blocked the throttle openings. so i decided to fix it. i wish i took a before pick of the intake tube but i didnt so just imagine it ok. after some heavy porting on the bottom and light on the top i matched it perfectly to the tb.
then i got to looking at the tb. i decided to edge the throttleblades. i used a cone stone and slowly touched it to the blade at a 45* angle. top front and back bottom. this allows air to enter sooner as the tb opens. then i took some metal off the throttleblade bar. you really dont need to since its not a race engine but i was board so what the hell.
next i took my stone onto the middle divider and didnt stop till i had a perfect airfoil. if you dont know what i mean, look up tpi airfoil on ebay. it helps feed air into the blades. then i took 1.5mm off the front opening then down to .5mm at the blades and the same on the back. this creats a venturi that forces air in faster. i thought it was bs too until a guy showed me on my saturn. so now looky:
isnt she a beauty. i also opened up that hole on the bottom for no apparent reason. so i bolt the sucker together and instant difference. much faster throttle responce and better feel thru the rpm range. then i decided to try something dumb. i removed the "black box" from the intake tube. i plugged it with an oil fill cap leftover from a pontiac gtp. fit perfectly into the hole. now even better responce, no buildup changin gears just smooth shifting up to redline and much more noticeable tire spin on the butt dyno. so thats my story. any questions?
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1995 nissan maxima se, 5spd short throw, aluminum flywheel and crank pully, stage 3 clutch, custom ported top end, full 2.5 exhaust jdm front end
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Axe Man
Kia Moderator Emeritus
Reged: 03/02/02
Posts: 4496
Loc: Highland, NY
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Very Nice!
A few observations: If you do soak the throttle body in carb cleaner I would NOT let the TPS get saturated. The carb cleaner could damage it. Also with regards to the TPS: it would be best to cut off the electrical connector and solder the wires directly to the TPS. That connector is notorious for developing contact resistance.
Unless you plan on porting the throttle body like you did I wonder how necessary it really is to remove it completely to give it a good cleaning. I just open the plates and clean them with carb cleaner at every plug change. Seems to work fine.
None the less...very nice pictorial.  Do you want me to sticky it as a maintenance item?
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1998 Sportage - Gone.
2004 Honda Civic Coupe.
2007 Suzuki Grand Vitara - She got it.
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flyboy367
Mudrunner
Reged: 06/24/05
Posts: 477
Loc: new jersey
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well when i worked in the dealership most of the guys that did the shortcut tb cleaning usually had thier cars coming back for o2 sensors. basically you fill up the intake with a flamable chemical then ignite it when you start the car. i always do the pulloff and never had a problem. you can sticky it if you want. it can be my one claim to fame
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1995 nissan maxima se, 5spd short throw, aluminum flywheel and crank pully, stage 3 clutch, custom ported top end, full 2.5 exhaust jdm front end
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fokion
Body Damage is Cool
Reged: 07/09/03
Posts: 1476
Loc: Athens Greece
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the differenses in sizes you saw between the parts and you grind them off, were there big?
I mean would you took all that appart just for that purpose?
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'96 4d mechanicaly stock so far, rims, spoiler, Cooper AT tyres, Factory LSD, Manual Warn Hubs, handmade exaust, ELECTRIC FAN!!! 3,1'' Lift, PALM GPS
http://members.cardomain.com/fokion
Edited by fokion (01/16/06 10:18 AM)
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flyboy367
Mudrunner
Reged: 06/24/05
Posts: 477
Loc: new jersey
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fokion, what your sayin is kinda greek to me 
i wanted to pull off the throttlebody just to clean it. i usually save p/p for performance cars, but i got board and went ahead on the kia. i didnt really mess any of my stones up so its a double plus. i figured since i had it all apart i wanted to see how it was. i always like seeing how stuff works. if you hold the tb an dthe intake tube together like they should be, then open the blades and look in you can see where all the extra metal is. it was a pretty big difference. in some spots almost 1/4" which pans out pretty bad. after the porting and smoothing, then going to town on the throttlebody and then ditching the stupid plastic bucket on the intake tube my truck will handle up to 40mph barly touching the throttle and i can floor it from 50 and just take off up to redline with no hesitation. for as easy as it is to take it apart id say go for it. at the least clean your throttlebody. you will see a difference there.
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1995 nissan maxima se, 5spd short throw, aluminum flywheel and crank pully, stage 3 clutch, custom ported top end, full 2.5 exhaust jdm front end
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logansportage
Body Damage is Cool
Reged: 04/22/02
Posts: 1217
Loc: Logan, Utah
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Great write-up!!!
Next time I've got mine apart doing plugs, I'm going to do this!
What kind of stones did you use? Did you just use a Dremel or something special?
Thanks
Logansportage 
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White 1998 4 door KIA Sportage 4x4 w/Eibach 2.5 spring lift and TJ rear coils, 4crawler 1.5 body lift, Monroe Sensa.trac shocks, Bosch 4+ plugs, Eaton LSD, 31x10.5x15 BFG KM tires, 2.5 cat back exhaust w/SpinTech muffler
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fokion
Body Damage is Cool
Reged: 07/09/03
Posts: 1476
Loc: Athens Greece
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Quote:
fokion, what your sayin is kinda greek to me
i wanted to pull off the throttlebody just to clean it. i usually save p/p for performance cars, but i got board and went ahead on the kia. i didnt really mess any of my stones up so its a double plus. i figured since i had it all apart i wanted to see how it was. i always like seeing how stuff works. if you hold the tb an dthe intake tube together like they should be, then open the blades and look in you can see where all the extra metal is. it was a pretty big difference. in some spots almost 1/4" which pans out pretty bad. after the porting and smoothing, then going to town on the throttlebody and then ditching the stupid plastic bucket on the intake tube my truck will handle up to 40mph barly touching the throttle and i can floor it from 50 and just take off up to redline with no hesitation. for as easy as it is to take it apart id say go for it. at the least clean your throttlebody. you will see a difference there.
so you DO understand Greek
You answered exactly what I was asking!!!!!!!
So It DOES worth grind the system.
AFAIK the same missmatch happens to the exaust header
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'96 4d mechanicaly stock so far, rims, spoiler, Cooper AT tyres, Factory LSD, Manual Warn Hubs, handmade exaust, ELECTRIC FAN!!! 3,1'' Lift, PALM GPS
http://members.cardomain.com/fokion
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fokion
Body Damage is Cool
Reged: 07/09/03
Posts: 1476
Loc: Athens Greece
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I would vote for "sticking" it
if you ask me
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'96 4d mechanicaly stock so far, rims, spoiler, Cooper AT tyres, Factory LSD, Manual Warn Hubs, handmade exaust, ELECTRIC FAN!!! 3,1'' Lift, PALM GPS
http://members.cardomain.com/fokion
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flyboy367
Mudrunner
Reged: 06/24/05
Posts: 477
Loc: new jersey
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Logan, i use the stone you get in a set at home depot. mostly the large cone, and a flat circular wheel. the cone is great to get your angle for tapering and putting an edge, the wheel is for taking off alot at a time. you really should use a dremel but im lazy and dont feel like paiting forever so i used my high rpm die grinder 
just be careful of flying aluminum.
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1995 nissan maxima se, 5spd short throw, aluminum flywheel and crank pully, stage 3 clutch, custom ported top end, full 2.5 exhaust jdm front end
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logansportage
Body Damage is Cool
Reged: 04/22/02
Posts: 1217
Loc: Logan, Utah
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Cool.
Yes, Flyluminum can be a pain in the eye  and ARSS  . Been there and done that. 
Logansportage
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White 1998 4 door KIA Sportage 4x4 w/Eibach 2.5 spring lift and TJ rear coils, 4crawler 1.5 body lift, Monroe Sensa.trac shocks, Bosch 4+ plugs, Eaton LSD, 31x10.5x15 BFG KM tires, 2.5 cat back exhaust w/SpinTech muffler
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