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2G throttle body plate should seal perfect?

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That is very bad. My bored out 63mm throttle body also isn't machined perfectly, and it is causing me grief. But it still is much tighter than what you have. I'd get a used 60mm 1g tbody and consider it an uprade.
 
^ great idea. But if you had your heart set on running that TB, you can always loosen the plate's screws that hold it to the TB shaft then fully close the TB (helps to center the plate in the bore) then retighten the screws.

-I had to do this on my 63mm bored TB as it also had some pretty bad gaps around the plate's circumference.
 
Is it sticky? I just rebuilt mine and I was haveung problems with mine sticking open. All I had to do was loosen the two screws that holds the plate in and then snap the throttle plate shut a few times. It straightened out perfectly. The same thing might help you too

Sent from my T-Mobile G2 using Tapatalk
 
Yes its inserted the correct way.
But i hit the plate with my pliers and it got some very littel deformation
I think this is the reason

Take the throttle plate off and try to GENTLY massage it back to flat with a rubber mallet being carefull not to make it worse than it already is. If that doesn't work, depending on how badly it's bent, you might be able to compensate for the increased airflow by screwing in the BISS.
 
You can also get some jb-weld or similar setting compound and use it to build up the bore a bit so that it matches the shape of the plate. Factory throttle-bodies are built this way and you'll see the greyish compound of you look at almost any unmodified unit.
 
First off, it should not fully seal. If it does, it will stick or just not open. You will have a thin space between the plate edge and the body. Do not try to get one machined to match the bore perfectly or use any material on the inside of the bore to build it up. That will cause issues with the throttle plate action and if you use material, it could possibly be sucked into the engine.

Does it stick at all when you open/shut it? Make sure to open it fully and let it slam shut. Then try to open it again. This is commonly when they will stick.

If you have a very thin gap, you should be just fine.
 
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