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[San]

Here is how to swap a 60mm DSM turbo or NA throttle body onto your 4G while keeping idle control functionality.

You will need:

High temperature rubber coolant hose.
You will need thin sheet metal (I used a floppy shutter).
Some silicone sealant.
Patience.
A phillips head screwdriver.
12mm socket.
Scissors or tin snips.
Probably a new gasket for between the IAC and TB.
Die grinder or Dremmel and bits (for Aluminum)

You may need new bolts if the mounting depth of your new TB is different. I needed to get new ones because my home made adapter was so thick.

There are three steps 1 performing the TB coolent bypass, 2 porting the manifold, and 3 the IAC swap.

1. The car must be cool and level. Find the coolant hoses that run into the TB. Reroute them into one aother with a new hose (or the longer of the two hoses). This will completely stop the coolant from flowing through the throttlebody. This is important because: You may not seal the new houring all the way, and your engine will inhale coolant and die, and this reduces the intake temperatures and improves performance.,

2. Get the throttle body gasket and some machinists blueing (or a sharpie). Bolt the gasket the the intake manifold without the throttle body. Mark the intake manifold for the 60mm opening. Now, port the intake manifold with the die grinder until the opening matches your markings. You can do this with the manifold in place, but it is recommended to remove the manifold and port it off the car. This way you have a more comfortable workspace, and less chance of pushing metal shavings into your cylinders. If you must port on-head, stuff a rag into the opening to keep the metal out of your intake. Be sure to vacuum the manifold well before starting the car. If you do this off the head , you can clean your intake manifold afterwords. Some folks like to take it to a self serve high pressure car wash, and blast the crap out of it, others like to use two cans of TB cleaner and kill a large spot of my lawn (stupid engineers).

3. Find a nice quiet spot to work. Unscrew the IAC housings from the two throttle bodies. BE PATIENT I stripped the screws on my turbo TB and had to buy a new set. Eight dollars for 5 screws is not funny. Besides when you strip them, they are very dificult to remove, due to the contours of the IAC housing.
Get your floppy shutter and your sturdy scissors or snips. Carefully cut out shapes to cover the holes that once held the coolant. Cut out a piece to cover half of the square (on the passenger side) of the Mirage IAC housing. Stick these pieces down with a little silicone, just to ensure they are airtight.

Check your work. Do your metal pieces completely seperate the chambers like they are supposed to? Are any of those metal pieces going to be sucked into your engine forcing costly repairs? Are you sure you will not ingest any coolant?

Bolt the housings back together (that is, Eclipse TB to Mirage IAC) They will be held together with three screws in the rear. You may wish to add some silicone to the non bolted side for insurance. Bolt your monster onto your manifold, and prepare for some nice gains.


Matt
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1995 Mirage LS Coupe