Hi does anyone know of any bigger throttle bodies from other fords that would fit straight on the 1.6 mk2.5? I have searched around but most seem to be for older versions.

There are no larger throttle bodies available for the 1.6 Duratec engine. The 1.25, 1.4 and 1.6 Duratec engines all use the same 45 mm throttle body. If you want a larger throttle body it needs to be custom made. The 1.8/2.0 Duratec HE engine has a similar throttle body design but the bolt pattern of the throttle body is completely different.

A few Years ago I modified a standard 45 mm throttle body to 50 mm. I machined the throttle body to 50 mm and installed a throttle plate from a weber carburetor. 50 mm weber throttle plates can be bought as a spare parts from a carburetor specialist. The weber throttle plate has exactly the correct angle for the Ford/Visteon throttle body.

Cheers for the reply. The current is quite throaty but feels like its needs more. What was the 50 like? I'm stuck with this car for a while so trying to make some things better. It is quite nippy for a 1.6 tbh the aftermarket filter makes it roar but you know what its like you just want more lol

In my opinion a 50 mm throttle body is a huge improvement. It makes the engine much more responsive.

Below some pictures I took when I modified the stock 45 mm throttle body to 50 mm.

I started with a donor throttle body I bought onine from a scrap yard.

 

After the throttle body was completely disassembled I cleaned all parts and ordered the 50 mm Weber throttle plate from an online seller. I also measured the exact size of both the throttle body bore and the throttle plate to determine the correct end play of the throttle plate. The stock 45 mm throttle plate has an end play of 0.05 mm.

 

After the 50 mm throttle plate arrived I compared it with the stock 45 mm throttle plate. The weber throttle plate has exactly the same bolt pattern as the stock throttle plate.

 

Next I enlarged the slot in the axle to make the larger throttle plate fit. Only bit of material needs to be removed to make the plate fit. I used a very smal file to do this.

 

I also chenged the bearing of the throttle body. These bearings are pretty cheap and can easily be changed.

 

Next I machined the throttle body to the correct size on a lathe. I used exactly the same end play (0.05 mm) as the original throttle plate. Afterwards I polished the bore and sandblasted the rest of the throttle body to obtain a perfect finish.

 

Finally I assembled the throttle body using all modified parts. I replaced the original alluminium blanking plate with a plastic blanking plate. The original blanking plate will be damaged during disassembly and can not be reused.

 

The throttle axle has a spring loaded stop screw which prevents the throttle plate for becoming stuck inside the bore when it is fully closed. In some cases it may be necessary to readjust this screw. My experience is that the measurements between the red dots need to be exactly 10 mm.

 

Except from the machining of the throttle body I did al modifications myself. The machining of the throttle body is performed by my father who is a lathe operator. This way the complete modified throttle body costed me less than €65,-.

 

 

 

 

 

Interesting thread and superb reply by JW1982  thanks for this I have liked this for you.

Very informative and excellent job! I guess it would mean getting machined then and no way would I attempt to dismantle it I would defo break it lol

Hi. I want to enlarge the throttle for my focus mk2.5 1.6 Ti-VCT. How do you remove the 2 screws to remove this 45mm plate? ? It twists halfway and doesn't go any further. Is there a pin?

I so need this on my 1.6, help me please wilco, I'll pay you

 

Hello Wilco, I've just been looking at this thread & it's still good after 11 years. I have a 2010 1.6 at 35k, RS type moulded front bumper, ST rear bumper with custom cat back & after market Fox 17'' rims. I will be getting KW V2 coil overs & poly bushes all round with a BMC CDA induction system but.... I have a new 45mm TB on the way from MaxSpeedingRods but nowhere to send it for boring. Can you or do you know someone who can help me with this? I'm keeping my car for many years to come, I know It's only a 1.6 but it's economical & she looks fantastic. Any help with this would be amazing?