2.5 Intake and Throttle body Swap using 2.0 sensor for 20$!!!
(Currently In Testing Phase Will be updated soon!!)
(Requires small weld)
Hey guys, I'm attempting to get us a mostly DIY method for 2.5 throttle bodies & Intake manifolds in our cars.
We will be modifying our current 2.0 TPS+Cover (all one unit) onto the 2.5 throttle body too make it work.
I have covered my findings, Cost, and How to Process in here.
![Image]()
Too be clear again, the Finished throttle body is un-tested and I will be posting the results soon.
If this works well, I will be willing to build them for an added cost if you require one.
...................................................
How to Guide is at the bottom.
....................................................
Specs: Stock Intake Volume = 3.75 liters
2.5 Intake Volume = 5.75 liters
34.8% Total Volume difference!
Stock Throttle body.. 2-1/8ish
2.5 Throttle body..... 2-3/8ish
I'll need too grab better measurements for this, but it is a noticeable size difference for sure.
The stock throttle bodies are very small in diameter and just swapping my 2,0 intake for a 2.5 makes a huge difference in stock power.
First off
Both TPS sensors are different Internally.
The 2.0 has a rectangular twist style male rod, that internally operates the tps sensor.
The 2.5 Has a twist rod That is chopped off and spins underneath a chip on the 2.5 TPS housing.
Which is them determining the tps Location.
This makes them operate differently and means our PCM's won't know what our throttle position is.
Even if you found out how to properly re-pin the 2.5 throttle body.
This lack of a proper TPS reading will cause a wheel torque error calculation in the pcm, and throw the car into limp mode when it reaches a certain error threshold set by the pcm. Which too be fair, can be expanded in Advantage III.
However, I've been there and done that already.
Why even try????
Hopefully to wake up our power band!! Our ports are small and not meant for power.
(08's would get an even better gain since they came with swirl flips)
It's a stock throttle body, for the stock 2.5 manifold.
And it's obviously cheaper than other Costly Big TB solutions.
More Info:
I started by taking apart the 2.5 throttle body and 2.0 throttle body, the gearing is different on each set.
2.0 gearing (18-88/16-17) (Tb-Motor) 4 Motor revolutions for WOT 2.5 gearing
(19-66/16-11) (Tb-Motor) 4.1ish motor revolutions for WOT Motor differences
(2.5 motor 2Amp Draw)
(2.0 motor 3Amp Draw)
Mounting points are different.
The good news is that despite all of the changes, The setup will Mechanically be capable too reach 97.5% Throttle angle from the previous WOT position.
Which is a small loss for a massive volume increase.
I believe this Mechanical loss can be regained in tuning software as well by adding the missing 1.35 degrees of angle back into the Maximum Angle in Advantage III Pro Racer Software. since the motors could spin around all day and the only limit is the tps gear hitting a wall.
How to do the mod.
Grab your 2.0 and 2.5 throttle body, (out of the car with a 8mm socket, tps clip, and a flathead for the clamp)
Get a T25 torx.. Remove the black covers. (Hard to mix up the parts btw)
Next, Grab your 2.5 throttle body..
We will have to drill out a hole in the case for the Pin on that middle gear..
Pull the gear up and it comes out.
This Gear is what sets the ratio in between the motors gear and the butterfly/tps gear.
Youll see what gear i mean if you try to put the 2.0 case on the 2.5 throttle body. The only one that interferes
You'll see how far off it is, This means you'll have to drill out the cover too make room for the rod.
It's not a big deal if its perfect it just has to hold the rod, If it doesn't, it may eventually bend the rod..
But i'd more than likely put money on the plastic gears breaking first before the stainless steel bending.
![Image]()
Next, wallow out the 3 out of the 4 Holes on the 2.0 cover that kind of line up.
Not by much. A millimeter or two. 1 hole wont line up, it will be pretty obvious.
![Image]()
Also theres a Gap that will need a little epoxy too hold in any escaping tb vacuum/boost)
![Image]()
Next, the corner Of the case above the TPS plug.
That has too be bitten off too clear the corner Of the TB housing.
I grabbed pliers and broke the chunk off.
![Image]()
Now the tps+cover will line up too the case, the rod has clearance, and it can be bolted on for a test fit.
Take note: Don't epoxy anything until the process is done and its tested.
![Image]()
Here's the big final step, tps Signal.
This is actually kinda easy with a table saw and a tig welder.
If you don't feel comfortable cutting and Welding, I recommend finding someone who is and having them do it.
Now. Grab the 2.0 throttle body, you'll want to cut the butterfly rod, right where it transitions too the rectangular shape that controls the tps. sensor.
![Image]()
Take mark of the 45-degree position with the right side down.
A Speed Square can be used to verify the position of the tps sensor when welding.
![Image]()
Prep, Weld, Reaseal, Epoxy, and Remount.
Have to go Pick the project up from the head shop that so generously welded it for me tomorrow.
I'll post and update tomorrow with it plugged in and see if it spins after i re-pin my tps wiring!
Parts and cost.
2.5 Throttle body 25$
Weld 20$
This is only a small chunk of change for the car it's going in. And was more or less too help my tuner out.
Enjoy!
Hopefully this is a good first post!
(Currently In Testing Phase Will be updated soon!!)
(Requires small weld)
Hey guys, I'm attempting to get us a mostly DIY method for 2.5 throttle bodies & Intake manifolds in our cars.
We will be modifying our current 2.0 TPS+Cover (all one unit) onto the 2.5 throttle body too make it work.
I have covered my findings, Cost, and How to Process in here.
Too be clear again, the Finished throttle body is un-tested and I will be posting the results soon.
If this works well, I will be willing to build them for an added cost if you require one.
...................................................
How to Guide is at the bottom.
....................................................
Specs: Stock Intake Volume = 3.75 liters
2.5 Intake Volume = 5.75 liters
34.8% Total Volume difference!
Stock Throttle body.. 2-1/8ish
2.5 Throttle body..... 2-3/8ish
I'll need too grab better measurements for this, but it is a noticeable size difference for sure.
The stock throttle bodies are very small in diameter and just swapping my 2,0 intake for a 2.5 makes a huge difference in stock power.
First off
Both TPS sensors are different Internally.
The 2.0 has a rectangular twist style male rod, that internally operates the tps sensor.
The 2.5 Has a twist rod That is chopped off and spins underneath a chip on the 2.5 TPS housing.
Which is them determining the tps Location.
This makes them operate differently and means our PCM's won't know what our throttle position is.
Even if you found out how to properly re-pin the 2.5 throttle body.
This lack of a proper TPS reading will cause a wheel torque error calculation in the pcm, and throw the car into limp mode when it reaches a certain error threshold set by the pcm. Which too be fair, can be expanded in Advantage III.
However, I've been there and done that already.
Why even try????
Hopefully to wake up our power band!! Our ports are small and not meant for power.
(08's would get an even better gain since they came with swirl flips)
It's a stock throttle body, for the stock 2.5 manifold.
And it's obviously cheaper than other Costly Big TB solutions.
More Info:
I started by taking apart the 2.5 throttle body and 2.0 throttle body, the gearing is different on each set.
2.0 gearing (18-88/16-17) (Tb-Motor) 4 Motor revolutions for WOT 2.5 gearing
(19-66/16-11) (Tb-Motor) 4.1ish motor revolutions for WOT Motor differences
(2.5 motor 2Amp Draw)
(2.0 motor 3Amp Draw)
Mounting points are different.
The good news is that despite all of the changes, The setup will Mechanically be capable too reach 97.5% Throttle angle from the previous WOT position.
Which is a small loss for a massive volume increase.
I believe this Mechanical loss can be regained in tuning software as well by adding the missing 1.35 degrees of angle back into the Maximum Angle in Advantage III Pro Racer Software. since the motors could spin around all day and the only limit is the tps gear hitting a wall.
How to do the mod.
Grab your 2.0 and 2.5 throttle body, (out of the car with a 8mm socket, tps clip, and a flathead for the clamp)
Get a T25 torx.. Remove the black covers. (Hard to mix up the parts btw)
Next, Grab your 2.5 throttle body..
We will have to drill out a hole in the case for the Pin on that middle gear..
Pull the gear up and it comes out.
This Gear is what sets the ratio in between the motors gear and the butterfly/tps gear.
Youll see what gear i mean if you try to put the 2.0 case on the 2.5 throttle body. The only one that interferes
You'll see how far off it is, This means you'll have to drill out the cover too make room for the rod.
It's not a big deal if its perfect it just has to hold the rod, If it doesn't, it may eventually bend the rod..
But i'd more than likely put money on the plastic gears breaking first before the stainless steel bending.
Next, wallow out the 3 out of the 4 Holes on the 2.0 cover that kind of line up.
Not by much. A millimeter or two. 1 hole wont line up, it will be pretty obvious.
Also theres a Gap that will need a little epoxy too hold in any escaping tb vacuum/boost)
Next, the corner Of the case above the TPS plug.
That has too be bitten off too clear the corner Of the TB housing.
I grabbed pliers and broke the chunk off.
Now the tps+cover will line up too the case, the rod has clearance, and it can be bolted on for a test fit.
Take note: Don't epoxy anything until the process is done and its tested.
Here's the big final step, tps Signal.
This is actually kinda easy with a table saw and a tig welder.
If you don't feel comfortable cutting and Welding, I recommend finding someone who is and having them do it.
Now. Grab the 2.0 throttle body, you'll want to cut the butterfly rod, right where it transitions too the rectangular shape that controls the tps. sensor.
Take mark of the 45-degree position with the right side down.
A Speed Square can be used to verify the position of the tps sensor when welding.
Prep, Weld, Reaseal, Epoxy, and Remount.
Have to go Pick the project up from the head shop that so generously welded it for me tomorrow.
I'll post and update tomorrow with it plugged in and see if it spins after i re-pin my tps wiring!
Parts and cost.
2.5 Throttle body 25$
Weld 20$
This is only a small chunk of change for the car it's going in. And was more or less too help my tuner out.
Enjoy!
Hopefully this is a good first post!
