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Date:         Wed, 14 Mar 2001 11:08:00 -0800
Reply-To:     "Scott G. Terry" <sgterry@ENGINEERING.UCSB.EDU>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         "Scott G. Terry" <sgterry@ENGINEERING.UCSB.EDU>
Subject:      1.9L throttle body leaks - overhaul questions
Content-Type: text/plain; charset="us-ascii"

Hi Listers,

I'm a new owner of a 1985 Westy, my first VW. She has 167K miles.

I took the throttle body out. Things don't look too good here. First, a small (~1/8" dia.) hole has been drilled through the butterfly!! QUESTION: Is this the factory setup? I'm assuming it isn't and plan to fill the hole with epoxy. Presumably a PO had idle problems and took drastic measures.

Also, the butterfly shaft (vacuum) seals have small cracks and don't seem to seal tightly around the shaft. My dealer does not list replacement seals. It looks like these seals are built to hold grease and maybe a dollup of new grease will be sufficient for vacuum sealing, but if anyone has suggestions for renewing these seals, please share.

Wear on the butterfly shaft and its supports have caused the butterfly to score the interior of the TB. This has made the operation of the valve a little sticky when opening from idle. I found that by adjusting the throttle valve mechanical stop screw, I've prevented the butterfly from traveling all the way into the scored area when closed, and now the butterfly opens without any sticking. (After this adjustment, the butterfly is still closed at idle, and the tiny vacuum port falls on the atmospheric side of the butterfly at idle. The adjustment moves the closed position of the butterfly fractions of a millimeter.) Short of machining a new butterfly shaft and bushings, this is the best way I could rectify the butterfly shaft/bushing wear. Comments?

Thank you!

Scott '85 Westy "Pearl" Santa Barbara, CA


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