Rebuild Turbo DSM Throttle Bodies

If you're having idle problems that aren't caused by boost leaks, do the electrical tests in this video, 1 minute can save you hours of head scratching. There are 8 tests, 8 positions that you can probe with a multimeter that will reveal a ton of information about your idle and throttle control system. Do these tests before you even bother with removing it. But if it's leaking boost (and it probably is now that it's almost 30 years old...) watch this video, read this description for parts info, and search for the part numbers to find vendors. You can fix it.

This video covers everything you never wanted to know about turbo DSM throttle bodies. Probably more. I'm putting this here as a resource for the community if for no other reason than because I have all 3 turbo throttle body models and I had to do it to one of them anyway. I ran into lots of issues because the one I had to rebuild was a 90. These are the oddest and rarest, hardest ones to source parts for. This is now the 5th, 6th, 7th, 8th throttle bodies I've rebuilt and I see 2 more in my future for sure. It's a job so commonplace to me I take it for granted... and in my mind, everyone already knows everything about how to do it.

Because:

There's already a ton of information about this on message boards, archived VFAQ's, and extinct image hosts. But someone needed to spend entirely too much time, effort and money to update the format. Something will replace YouTube in a few years, and my efforts can die here just the same. This takes nothing away from all the great people who have posted info on this topic. They have all genuinely helped the community. It's because of their efforts over the years that anyone is still talking about this at all today. There are other videos on this subject, too. Those people should tag me in their video info-so that their videos will stand a chance against what Google's algorithms want my viewers to watch. Remember when the recommended videos were actually on-topic with the one you're watching? I don't want to be the only source of anyone's info. I'm just throwing myself into the pile.

As for the viewers, if you do exactly what I do, the same way I do it, you'll only have the same results I achieve. ...which is okay in the case of this video... but I want all of you to be better than that.

The channels I recommended in the video indeed are both friends of mine. I pull no punches. They're friends, and they make DSM videos. They both contributed to my production AND to this topic. They've helped me an awful lot over the years. If you like DSM content, click their subscribe buttons and the worst thing that could happen is you'll get more DSM-related content. If this helped you, it's a free way to give back to the community. I promise you won't get spammed.

Jason Drew:    / jdxnc04  
Boosted Beaver:    / robertbaxley  

How to disable FIAV:
1990 -    • Closing the FIAV - The Free Way  
1991-1999 - http://bfy.tw/KHmX

Part numbers:
MD614948 - All Years - BISS Screw (they're all plastic now)
MD608806 - All years - BISS Screw O-ring (6x10x2mm)
MD614417 - All Years - ISC Motor O-ring (028 1.364 .070")
MD614406 - 1991-1999 - FIAV gasket
PSI-01512 - All Years - Throttle shaft seal (large)
G8X12X3B - 1990 - Throttle shaft seal (small)
MD614216 - 1990-1994 - Throttle Switch
MD614590 - 1991-1994 - Throttle Position Sensor
MD614662 - 1995-1999 - Throttle Position Sensor
???????? - 1990 - ISC Motor (out of production, use 1991-1999 part)
MD628051 - 1991-1999 - ISC Motor
???????? - 1990 - TPS Sensor (out of production, $? used to $339)
MD614559 - 1991-1994 - TPS Sensor 1g
MD614662 - 1995-1999 - TPS Sensor 2g
MD125822 03/89-06/90 TB Gasket (to intake manifold flange)
MD146399 06/90-05/94 TB Gasket (to intake manifold flange)
MD184046 - 1995-1999 - TB Gasket (to intake manifold flange)
MD340327 03/89-07/92 TB Gasket (to TB elbow)
MD194827 08/92-05/94 TB Gasket (to TB elbow)
MD302262 - 1995-1999 - TB Gasket (to TB elbow)
1990 - Throttle Shaft E-clip (OD must be 1/2", ID 1/4", file for fit)
https://www.fastenal.com/products/det...

All Years - Throttle Plate Screws
M4 0.7 10mm machine screw
https://www.fastenal.com/products/det...

Unfortunately, CAPS does not reveal any further details beyond the gaskets and the throttle body as a complete assembly. Believe me, I was disappointed. Then I discovered that all years of service and overhaul manuals did not cover this procedure. Perhaps Mitsubishi did not intend for these to be rebuilt? Did not trust their mechanics? Perhaps they simply underestimated their enthusiasts? People who intend to keep a car running beyond its designed lifespan are going to find a way.