took off the tb and the entire intake manifold 2 days ago, i havn't had a lot of time to work on it so far but it is coming along. so far the tb has been modded, and porting has begun on the upper manifold. I will put up pics hopefully tommorow of the various steps.

I came across a few questions though that hopefully some experienced people could help with.

first, the bacv, can it be taken off and if so, aside from rerouting coolant and making a block off plate, what would need to be done with the vacuum lines? do they just get plugged.

second, the egr valve, i will remove that and put a plate there, but agian, do i just plug the vacuum lines?

i have no emmissions equipment on the vehicle and want to have the minimum amount of crap when i put things back together. Thanks guys, pics tommorow hopefully.

 

sounds like you are making headway. Good luck with the rest of it and I am lookin forward to seeing the pictures.

 

i searched on these questions but did not get clear answers. I need to know pwople, polease help. what do i do with the vacuum lines to the egr when i remove it, just plug them. alos can i remove the bacv and just reroute the coolant and plug any vacuums?PLEASE HELP ME> i want to put the car back together soon, need to know

 

THe BAC valve comes off. Cap the lines to it. The egr comes off. Cap the line to it.

 

I ground the entire ACV and EGR boss and passage between the intake runners off my TII lower intake and had the EGR port and little vacuum holes welded up as well as backfill on the EGR intrusion so I could cut that out of the runner. I just painted my manifolds etc, so I will post pics this coming week.

 

[IMG]//https://www.rx7club.com/forum/attachment.php?s=&postid=895573[/IMG]

 

 

i will post some pics later of the finish ports on the manifolds. also going to start to make some block off plates, as well as trying to shine up the outside of some of the parts that i have off right now.

While porting the upper intake manifold, i noticed that the casting had some seams in it that needed to be smoothed over. I also tried to make the passage of air to be as smooth as possible, all the turns were smoothed out as much as possible, especially on the top of the upper intake. I also grinded some of the seams off on the outside. I guess mazda didn't feel the need to trim off the excess materials after casting. oh well there gone now. I used a dremel to port with two different bits, one that was straight on the top and another that was rounded, the straight one wasa good at the top to take some serious stuff out, the round one cleaned up the job as well as went in deeper to clean and smooth things out. worked pretty well. I took my time on the poting, probably 5 hours on both manifolds including the time to clean out the metal chunks and filings, as well as a finish sand by hand. looks pretty good. i will get pics up of everything later tonight.

 

Awesome! I never did the full TB mod, just remove secondary plates. So I can't help with that BAC / ACV stuf.....

Yeah, porting is simple, just imaging air or water flowing through there and make it all as big and smooth as possible.

Please reply back with the power gains you can feel, I am curious as to how well it works on the S4's .

 

no problem, i am very anxious to get everything back together myself, but i don't want to rush the job. i will clean the **** out of everything, dirt= unnecesary weight. I also did the power steering mod, in wich i removed the pump, blocked the 3 lines onn the steering gear, and then cut the thin lines and hooked them together so the fluid will flow. hoping to save enough money to get an e fan,what cfm do i need? does anyone know, also, i would probably have to upgrade alternators to possibly an fd alternator.

 

many thanks to everyone especially hyntyz7 and felix wankel for answering some important qustions i had, tommorow i can start taking off the spider and than reassembling the intake manifold and tb/ dynamic chamber. I keep leaving the camera at my parents house with the car so no pics today. i have painted the manifolds with vht racing red brake caliper paint( had some left over from brakes), So far it seems to be looking really good, we'll see when the masking tape comes off and their reassembled.

 

heres some pics for yall!!!!!!!!!!!!!!

 

almost finished reassembling everything. I made block offs for the egr, and the bac, as well as acv. I disconnected pretty much all the vacuum lines except for the omp, boost sensor, brake booster, and fpr. i ran new fuel lines from the rails straight to the filter and return line. The rest of the vacuums i am just capping off. I took out all the hard lines as well.

 

Looks good

 

does anyone know what do to with all those clips from the removed solenoids?