covertrussian Posted July 24, 2017 Share Posted July 24, 2017 (edited) Recently built my own TGV's and figured I would do a quick writeup with how I did them. Tools needed: Die Grinder (I used a compressor one, drill might work?)Carbide burr bitsDremelSanding WheelsPolishing Wheels Parts needed: 4 x 1/8 NPT Plugs with Allen key ends. First thing I did was remove the butterflies themselves. You wont be able to unscrew them easily since the screws are flared at the end, to prevent them from walking out. Thus I ground off the threaded parts of the screws and then they easily came out. http://legacygt.com/forums/attachment.php?attachmentid=252875&stc=1&d=1500862257 Next up is puling out the bar, apparently there is a way to tap it out in one piece. I didn't get that memo and broke mine (that's why I got a spare). http://legacygt.com/forums/attachment.php?attachmentid=252876&stc=1&d=1500862257 With the butterfly bar out, you can now see the parts that need to be ground off. The obvious one is the divider, but the one that is sometimes missed is the lower lip, which also will impede flow. http://legacygt.com/forums/attachment.php?attachmentid=252877&stc=1&d=1500862257 Now the hard work begins... I used a carbide burr to cut the divider off, you can use a little saw too. http://legacygt.com/forums/attachment.php?attachmentid=252878&stc=1&d=1500862257 The upper divider is done, now it's all about smoothing everything out http://legacygt.com/forums/attachment.php?attachmentid=252879&stc=1&d=1500862257 Hard part is done, all 4 are roughly sanded with the dremel, you can try to get it mirror smooth on this point, I personally didn't see the need for such a small piece of the intake plenum. http://legacygt.com/forums/attachment.php?attachmentid=252880&stc=1&d=1500862257 At this point I tapped the holes with a 1/8 NPT bit, to install the hex plugs. On one side you will find a metal sleeve that needs to be removed, hard to get out but I was able to tap into it and it came out at that point. Make sure you don't overtap, or the plugs will protrude into the runners! http://legacygt.com/forums/attachment.php?attachmentid=252881&stc=1&d=1500862257 Hole is plugged, I used some red loctite for good measure http://legacygt.com/forums/attachment.php?attachmentid=252882&stc=1&d=1500862257 Here is the finished plug installed and not protruding. http://legacygt.com/forums/attachment.php?attachmentid=252883&stc=1&d=1500862257 All done and ready to be test fitted, but first we need to remove the manifold and stock TGV's. http://legacygt.com/forums/attachment.php?attachmentid=252884&stc=1&d=1500862257 Removing The Manifold & TGV's First drain the fuel rail (let it sit a couple days or pull the fuel pump fuse, start the car and let it die, that should drain most of the pressure). Afterwards you can unplug the fuel lines and all the vacuum lines, there are plenty... http://legacygt.com/forums/attachment.php?attachmentid=264900&stc=1&d=1525744186 Remove the intercooler, I also removed all of the throttle body screws at this point since I didn't want to undo the throttle body heater lines and introduce air into the coolant system. After that start working on all of the manifold and TGV bolts. Don't forget to undo the ECU grounds on the driver side TGV's. http://legacygt.com/forums/attachment.php?attachmentid=264901&stc=1&d=1525744186 I tried to pull the manifold out without removing the TGV's, but there is one bolt, that connects the fuel rail to the manifold that's unreachable. Thus the first time around you'll have to remove the manifold and TGV's at the same time. http://legacygt.com/forums/attachment.php?attachmentid=264902&stc=1&d=1525744186 http://legacygt.com/forums/attachment.php?attachmentid=264903&stc=1&d=1525744186 Here is the bolt that you want to remove if you want to be able to remove the manifold without removing the TGV's in the future. http://legacygt.com/forums/attachment.php?attachmentid=264904&stc=1&d=1525744186 Finishing Up The Porting Work With the manifold and TGV's off, The final step to porting is test fitting them on your motor and port any areas that protrude compared to the head. http://legacygt.com/forums/attachment.php?attachmentid=264897&stc=1&d=1525743665 You can see the parts that I didn't get as rounded in this before and after pic. Be careful not to over port, like I did a little, otherwise the TGV will be bigger then the head ports creating flow walls. http://legacygt.com/forums/attachment.php?attachmentid=264898&stc=1&d=1525743665 Reinstallation Attach the fuel rail to the TGV's, now we are ready to reinstall everything piece by piece http://legacygt.com/forums/attachment.php?attachmentid=264905&stc=1&d=1525744186 Installed the TGV's & fuel rails first, without that pesky fuel rail bolt, this was a piece of cake. http://legacygt.com/forums/attachment.php?attachmentid=264906&stc=1&d=1525744186 Final shot of the ported TGV's installed: http://legacygt.com/forums/attachment.php?attachmentid=264899&stc=1&d=1525743665 Rest is pretty self explanatory, install the manifold, all the vacuum lines etc. Disabling the CEL's Final step is to disable all of the TGV related CEL's otherwise your car will be stuck in limp home mode. (P2004) TGV - INTAKE MANIFOLD RUNNER 1 STUCK OPEN (P2005) TGV - INTAKE MANIFOLD RUNNER 2 STUCK OPEN (P2006) TGV - INTAKE MANIFOLD RUNNER 1 STUCK CLOSED (P2007) TGV - INTAKE MANIFOLD RUNNER 2 STUCK CLOSED (P2008) TGV - INTAKE MANIFOLD RUNNER 1 CIRCUIT OPEN (P2009) TGV - INTAKE MANIFOLD RUNNER 1 CIRCUIT LOW (P2011) TGV - INTAKE MANIFOLD RUNNER 2 CIRCUIT OPEN (P2012) TGV - INTAKE MANIFOLD RUNNER 2 CIRCUIT LOW (P2016) TGV - INTAKE MANIFOLD RUNNER 1 POS. SENSOR LOW (P2017) TGV - INTAKE MANIFOLD RUNNER 1 POS. SENSOR HIGH (P2021) TGV - INTAKE MANIFOLD RUNNER 2 POS. SENSOR LOW (P2022) TGV - INTAKE MANIFOLD RUNNER 2 POS. SENSOR HIGH Edited May 8, 2018 by covertrussian 05 LGT 16G 14psi 290whp/30mpg 12 OBP Stock 130whp/27mpg@87 Oct 00 G20t GT28r 10psi 250whp/36mpg Link to comment Share on other sites More sharing options...
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