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Discussion Starter #1
Hi,

I have an 09 MK1. I have discovered that my throttle body does not mate fully with the intake manifold, causing the engine to judder at 2k revs and high load (air/fuel mix off)

I have taken the TB off and the checked the housing (100% intact), the seal ring is solid and I surmised that this is the issue. As a temporary solution, I made a new seal out of liquid gasket maker, which worked for a few days (noticeable power increase, responsiveness, and no juddering) until the seal just blew out.

I have now put the original seal back in and it's back to its original shenanigans. But hey it's better than no seal right?

Ford decided that they don't sell the seal for it. I begrudge paying ford £400 for a new TB, and even £150 for an aftermarket TB when all I need is a new seal. Has anyone found a seal for another make/model that works in lieu of this? I have been googling for an answer but nothing concrete.

TL: DR - Any suggestions for a replacement mk1 throttle body seal?

Cheers

Craig
 

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Discussion Starter #3 (Edited)
Which engine?

The Mk.1 uses a Peugeot designed engine soaPSA dealer parts department may be an option.
2.0 TDCI 136 AWD

EDIT: Found that the same throttle body is used on Peugeot 407 2.0 HDI as well as Citroen c5 2.0. Scouting around these vehicles as it looks possible to get seals.

Cheers
 

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Discussion Starter #4
UPDATE:
So today I decided to kiss the situation....yup.... Keep It Simple, Stupid =D. Suspected TB to intake seal leak (see above for attempted remedies). I wrapped the flange joint in duct tape to see if that made any difference. Wee jaunt up the motorway later; car felt nippier (wasn't sure if that was just in my head since I was hoping for a change), also, the miles left in the tank had jumped up around 20 or so extra. So when I got home, I scanned the car for any DTCs that didn't turn on the MIL (previous experience on this very issue) aaaannnndd......boost pressure exceeded known limit. Perfect! Duct tape sealed the leak, allowing full turbo airflow, and upsetting the ecu learned values at the same time. Bad news; vibrations are still there. Poked around the engine mounts, which are on my list of things to do this weekend, and I think (correct me if I'm wrong) they are hydro-filled mounts.... the rubber on my RHS mount is cracked and all saggy. This is pushing me towards the mount being the source of the vibrations.

TL DR - Throttle body knackered - not source of vibrations. Engine mounts all cracked and sagging; still to replace.
 

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Many years ago my mothers 1.3 ford escort (push rod engine) did 70+ mpg but had no power.
(no computer wotsits then)
The fault was inlet manifold gasket, sucking more air in, which is in some regards similar to your problems.

Regarding vibration. Engine mounts yes, engine tends to rock back with a foot full, also look at torque control arm.
Lower engine mount, behind gearbox will attach to lower subframe somewhere.
 

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Discussion Starter #6
Quick update - Fitted a new OS engine mount over the weekend, this has fixed general responsiveness and given the car a livelier feel, however it hasn't sorted the vibrations in question. I have fitted a new throttle body with a new seal today; will update later if this resolves the issue.
 

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Discussion Starter #7
Update:
Engine starts up and shuts down 100% smoother, car pulls like a beast on a mission, responsiveness is up and fuel economy is up. Think my issues with the TB were both the seal as well as the anti-shudder valve. However this hasn't solved my vibration issue. The dog-bone mount is slightly more involved, as there is another trans mount in the way, that requires extra brackets to be removed...too much for -4oC weather work.
 
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