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 Post subject: DIY: Throttle body install with port match intake manifold
PostPosted: July 2nd, 2008, 10:24 am 
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New to this Colt stuff
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Joined: November 15th, 2007, 1:47 pm
Posts: 33
Location: Sydney
Model: CJ (1996 - 2004)
I made this guide for mitsu owners.
applicable to 4g93, 4g94, 4g15, 4g92.
You might find the info interesting regardless. So enjoy.
SAFEFY FIRST.
I used a dust mask and googles.
I got hectic dust mask i use with MDF but for this i just used a regular mask since there not that much dust when using carbide burrs.
Also other PPE may be suitable.
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Im just going to plop a slab of steps in no real particular order as logn as you get the point.
This might apply to other cars but was done on a Mirage with 4g15 engine with 4g93 throttle body upgrade.
If i missed any steps just refer to pictures for hints.
4g15 sohc = 45mm
4g93 sohc = 50mm.
Port matching 5mm diameter (effective 2.5mm radial increase)
Expect mid to top end gains.
More throttle response (some say its a placebo)
Tools required etc:
-Air compressor
-rags
-Vacuum cleaner
-newspaper
-TB carby cleaner
-WD40 to lube and maintain the carbide burr (munches through the manifold quicker
-air die grinder with preferable 6mm collet
-carbide bur bits (recommend tree bur, or rectangular with rounded edge to prevent the tool bit from buckling under using.) I dont recommend stone grinding bits because they put out too much fine dust which is probably more toxic then shavings.
-socket set
-spanner set
-rubber mallet
-optional 8mm (5/16 fuel hose)
-optional male-male 5/16 (8mm) hose adaptor
-Mask and googles
- Remove the plugs from the TPS and the IAC
- Use a knife to pop the metal clips on many jap cars. Pry the clip out. If you try to yank it without prying the clip you will just break the connector.
- Throttle body bolts are 12mm and will be tight over time. Just attach a long bar, torque wrench to crack it. No problem. Remove them.
- Break the gasket seal with a rubber mallet.
-Once free maneuver the TB around and use pliers to slide the spring clips down the 2 hoses for the coolant pass through lines.
-If you can wedge a screwdriver as leverage it will be very easy to pop the seal of the hose. Otherwise pry a bit to break the seal and twist/pull it off.
- Put some M9/M10 bolts into the hoses for now to prevent coolant from leaking too much. Not a big deal. Only some will come out.
-Ok now clean up the mounting area, fit the gasket on, and use a marker to mark the area to by ported out.
-Shove a clean rag into the manifold and at the end fold it up and then pack it to prevent shavings from going down the runners.
- Go slow, use wd40 every few minutes to lube and maintain the carbide bur bit.
-Use a vacuum to clean the area to make it easier to work with.
-When done you might want to smooth the ridge on the actual manifold hole with the enlarged hole. Use a tree bit since its easier.
- After you are done here remove the rag in one slow motion. There wont be any shavings further then the outer opening itself if you took care. Clean up the area.
When mounting the new TB you have 2 options.
-Run the coolant line back in if it fits.
- If the line points the wrong direction it its a hard fit you can do a coolant bypass.
-The 2 hoses that run out of the engine can just be linked together.
- Dont do this is you live in icy areas since the coolant passing through the TB is there to prevent the butterfly from sticking.
- You could say doing the TB coolant bypass allows the TB to operate cooler and you get more power.
-You can fit some vaccumm caps on the open fitting if doing the coolant bypass.
If you are transferring TPS. Some cars you can just measuring the resistances using an ohmeter from pin 1-2 1-3 1-4 etc and set it same on the new TB.
On other cars like mitsu pin 3-4 is an open circuit when the TB is closed and closed circuit (0ohm) when the TB is open. Of course you can just set it via the TPS voltage as long as the clsoed throttle is from 0.3V to 1V and WOT is 4.5-5.5V but you will check engine light at idle if pin 3-4 is not calibrated.
For this as long as the TPS is good you only need to set the idle circuit again for the TPS.
-Put a 0.45mm feeler gauge or close to 0.45mm (i just used a imperial one and convert the thickness) If the gauge doesnt have the exact value just double up on the relevant attachments.
Put it in between the throttle stopper and the screw.
THEN set the idle circuit as above.
Rotate the TPS anticlockwise and you will see the pin 3-4 is continous.
NOW rotate it clockwise and stop when the pin 3-4 is open circuit.
ONCE it is done tighten the screws, remove the feeler gauge and check it the TPS operation.
CLOSED THROTTLE POSITION pins 3-4 must be continuity. ANY OTHER POSITION (ie move the throttle just a tiny bit) should give an open circuit.
As for ISC motor.
Some cars can just reuse the original ISC on the larger TB if its from the same or similar engine family. If it uses the same type anyway and has the same connector just leave it intact.

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White Mirage Hatch 4G15 Turbo (rear ended, written off)
Red Lancer MR 2door Mivec (sold)
Red Mirage Evolution 4g63


Last edited by iced on July 2nd, 2008, 10:39 am, edited 2 times in total.

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 Post subject: Re: DIY: Throttle body install with port match intake manifold
PostPosted: July 2nd, 2008, 10:25 am 
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New to this Colt stuff
New to this Colt stuff
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Joined: November 15th, 2007, 1:47 pm
Posts: 33
Location: Sydney
Model: CJ (1996 - 2004)
not on here too often but hope you guys find my guide interesting

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White Mirage Hatch 4G15 Turbo (rear ended, written off)
Red Lancer MR 2door Mivec (sold)
Red Mirage Evolution 4g63


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 Post subject: Re: DIY: Throttle body install with port match intake manifold
PostPosted: July 2nd, 2008, 12:11 pm 
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Joined: October 12th, 2007, 10:16 pm
Posts: 2378
Location: romsey, hampshire
Model: CJ (1996 - 2004)
: 2.0 v6 24v mivec cj mirage
thats is interesting to read :D im thinking on boring out my 6a12 plenum to match the tb.

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 Post subject: Re: DIY: Throttle body install with port match intake manifold
PostPosted: July 2nd, 2008, 6:18 pm 
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Totally Addicted to Colt!
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Joined: October 7th, 2007, 10:23 pm
Posts: 1898
Location: Wigan, Lancs
Model: CJ (1996 - 2004)
: 4g93t
good write up buddy.... exactly how i did it... i just didnt take pics :P
admin sticky??? will also apply the same to CA's?

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 Post subject: Re: DIY: Throttle body install with port match intake manifold
PostPosted: July 2nd, 2008, 11:04 pm 
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Joined: October 8th, 2007, 10:23 pm
Posts: 4802
Location: Coventry, UK
Model: CJ (1996 - 2004)
: CJ RS EvoBorg 99% Complete
yeah good write up dude! will do that with a 4g63 TB if i can find one lol


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 Post subject: Re: DIY: Throttle body install with port match intake manifold
PostPosted: November 19th, 2008, 12:17 am 
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Joined: April 17th, 2008, 6:49 pm
Posts: 3624
Location: Reading
Model: CJ (1996 - 2004)
Hi , ive bought an evo 4,5,6, throttle body and followed your method as best i could, but im having a problem with the idle of my car. It starts but then stops and it only stays running if i keep my foot on the accelerator. Ive also noticed the butterfly/valve doesnt fully oppen on full throttle. Have i done sumthing wrong. Also another thing that i noticed was i hace 3 small hoses that went into the top of my last throttle body but the evo 1 only has 1 tube bit on it to put 1 of the pipes on. (Its got letters on the top. P,E,A, i think) Your help would be greatfull as i would like to get the car back up and running before the weekend so i can go to a meet in hatfield, Cheers.

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 Post subject: Re: DIY: Throttle body install with port match intake manifold
PostPosted: November 19th, 2008, 12:27 am 
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Joined: September 26th, 2007, 6:14 pm
Posts: 3864
Location: Ruskington
Model: CJ (1996 - 2004)
: 1.5 Mirage Coupe (Asti)
J-man wrote:
Hi , ive bought an evo 4,5,6, throttle body and followed your method as best i could, but im having a problem with the idle of my car. It starts but then stops and it only stays running if i keep my foot on the accelerator. Ive also noticed the butterfly/valve doesnt fully oppen on full throttle. Have i done sumthing wrong. Also another thing that i noticed was i hace 3 small hoses that went into the top of my last throttle body but the evo 1 only has 1 tube bit on it to put 1 of the pipes on. (Its got letters on the top. P,E,A, i think) Your help would be greatfull as i would like to get the car back up and running before the weekend so i can go to a meet in hatfield, Cheers.


Did you reset the ECU to let the ECU 'learn' again? Take the battery off for 10mins then connect it back up. Finally start the car. The engine should 'search' for the perfect idle, it'll do this by going up and down in rev's. This is because the ECU is looking for the perfect air/fuel ratio mix. You putting a bigger TB on might be confusing it. That's where i'd start. Oh and whilst the ECU is learning don't rev the engine or drive it. Just wait next to the car for 5 mins!

Joe

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Disclaimer: Everything that I post on this forum I claim to be fact, through either doing it myself, assisting others directly or from 'Coltman'. Whether you choose to take my advice is your choice



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 Post subject: Re: DIY: Throttle body install with port match intake manifold
PostPosted: November 19th, 2008, 12:38 am 
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Joined: April 17th, 2008, 6:49 pm
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Location: Reading
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Ok, i will try that 1st, but i dont understand y the valve isnt opening fully. Can the throttle cable be adjusted ? If so how and ? And also the the three pipes situation. What do i do with them ?

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 Post subject: Re: DIY: Throttle body install with port match intake manifold
PostPosted: November 19th, 2008, 12:54 am 
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Joined: September 26th, 2007, 6:14 pm
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Location: Ruskington
Model: CJ (1996 - 2004)
: 1.5 Mirage Coupe (Asti)
The throttle cable is on a plate thats bolted to the inlet manifold. It has slots on it and to adjust simply undo the bolts and slide to the new position.

Joe

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 Post subject: Re: DIY: Throttle body install with port match intake manifold
PostPosted: November 19th, 2008, 8:26 am 
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I thought it was that. But what about the pipes ? What do i do with them ?

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 Post subject: Re: DIY: Throttle body install with port match intake manifold
PostPosted: November 19th, 2008, 1:50 pm 
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Started to go a bit Colt crazy!
Started to go a bit Colt crazy!

Joined: January 14th, 2008, 3:12 pm
Posts: 755
Location: york!
Model: CJ (1996 - 2004)
nice read, im not massive on the ins and outs of engine stuff but i may just have a crack at that. ive gota 1.6 cj 99 plate, what would be the best and easiest TB for me to buy/moddify? i.e which evo 1/2/3/4/5? is there anything i need to look for when getting one? low milage engine etc or are they pretty much the same? plus would you say the gains are worth while doing the mod for?
cheers guys.


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 Post subject: Re: DIY: Throttle body install with port match intake manifold
PostPosted: November 19th, 2008, 7:58 pm 
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here are the pipes that i keep ging on about. what do i do with them cos there is nowhere to put them.

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 Post subject: Re: DIY: Throttle body install with port match intake manifold
PostPosted: December 6th, 2008, 9:36 pm 
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Started to go a bit Colt crazy!
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Joined: October 15th, 2007, 8:10 pm
Posts: 843
Location: Gillingham Kent
Model: CJ (1996 - 2004)
get a plastic T pipes link them all, u will find them they use it to link two washer Jet under bonnet,
u can buy those plastic T pipe from Halford

about the Idle problem, u got the Adjust the Throttle Position Sensor and the idle control screw,
as the idle setting were for EVO engine, not for 1.3 or 1.6 engine
also those pipes are link to some electrical parts, it may effect the idling as well

so get those pipes connected first, than adjust it when cold start, just try to get the car stay idling and keep it running
than do what Joe21 told u to do reset ECU, than adjust it again,
u got to set and adjust it correctly, when cold start and when engine is fully warm up,


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 Post subject: Re: DIY: Throttle body install with port match intake manifold
PostPosted: December 6th, 2008, 11:12 pm 
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Cheers for that, but ive already done it lol. Got a m8 of mine to do it as hes done this loads of times on his other cars. Cheers though. and as for those pipes, i made my own thing up using a bit of pipe and the metal pipes off of the old throttle bodie. will try and take a pic 2moro to show you.

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 Post subject: Re: DIY: Throttle body install with port match intake manifold
PostPosted: December 7th, 2008, 4:38 pm 
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Started to go a bit Colt crazy!
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Joined: October 15th, 2007, 8:10 pm
Posts: 843
Location: Gillingham Kent
Model: CJ (1996 - 2004)
that is great, good to hear it run well


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 Post subject: Re: DIY: Throttle body install with port match intake manifold
PostPosted: April 26th, 2011, 12:34 pm 
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Started to go a bit Colt crazy!
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Joined: March 16th, 2010, 10:22 pm
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Location: Norwich
Model: CJ (1996 - 2004)
Could you use a TB of an evo 7,8,9? as In after machiningthe inlet manifold is it plug and play or have you got to alter things aswell!?
cheers

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 Post subject: Re: DIY: Throttle body install with port match intake manifold
PostPosted: April 26th, 2011, 6:17 pm 
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Chris jman is selling a mivec and gsr throttle body if that helps.


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