Well i must say that this was a mission...
The reason: The sr20de throttle body is much larger than the bluebird throttle body. .[IMG]
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[/IMG]Throttle response and more air entering the manifold are always good things. The best way to not repeat myself here is for you to read this thread.
http://www.sr20forum.com/turbo/21729...-vs-bb-tb.html
Now to start: [IMG]
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Obviously you will need to remove the intake piping from the throttle body and get it out of the way. You definitely need some room to maneuver in there.
Next: [IMG]
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Go ahead and pull the throttle link off of the spring linkage above it, I chose to take it off the top because there is a little more room and less knucklebusting.
Next: [IMG]
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Pull the TPS sensor out of it's socket
Next: [IMG]
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Take the four allen head bolts out of the TB.
Next: [IMG]
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Now this is a pita. Slide the pinch clamp off of the hoses and remove the hoses...sounds easy enough but it's so damned tight in there, that it can be difficult. I removed the small hose off of the carbon canister first and then the front one, and then the back one. Some coolant will spill out when you pull the hoses off so make sure your dogs aren't around licking it up.
Next: [IMG]
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This is what things should look like with the bluebird TB removed...
Next: Remove everything from the donor DE TB. The way to do this is to take the two screws out of the inside of the TB on the butterfly itself. Put plenty of pressure on them when you back them out, they tend to strip just like the injector caps.
Now, turn the butterfly sideways in the TB and slide the plate right out. [IMG]
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Take the jam nut and lock washer off the end of the throttle shaft and slide everything off of the shaft. Some of the springs and washers need a little side to side persuasion. The stop at the very bottom of the shaft is the hardest to get off. I took a screwdriver and slid it between the TB and the stop and turned it sideways to wiggle the stop off the shaft[IMG]
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asap just take an open ended wrench and put it behind the stop and hammer the wrench to slide the stop off the end of the shaft.[IMG]
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Now everything is off the TB except for the shaft.[IMG]
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Leave the shaft in the TB, there is no need to change it out. I took a pic of the shafts next to one another so you could see the difference and why we need to keep the DE shaft in the DE TB.[IMG]
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If you'll notice, the DE shaft has a larger slit to accomodate the larger butterfly plate, the bluebird shaft WILL NOT WORK. Trust me i tried this first not paying attention. You may notice that the prong for the TPS's are a little different, nevermind this, they still work exactly the same.
Note exactly how everything came off of the shaft, things need to be put back on the same exact way when swapped.
Take the bluebird TB apart the same exact way as the DE.
Now take the bluebird parts and slide them on the DE shaft the same exact way they came off the bluebird TB. When you go to slide the throttle link on the end you'll notice that it hits the metal peg that holds the springs, and you may also notice that the bluebird peg is much shorter than the DE peg, because it doesn't have to accomodate the throttle linkage itself, only the double threaded link that goes up to the linkage. So, yep you guessed it, get out the old dremel tool and cut that badboy off to where it still holds the springs but does not interfere with the linkage.[IMG]
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Now slide everything back on the shaft the way it goes and you'll notice that the threaded part is no where near long enough to hold all the springs and washers and non sense tight. Well, my first thoughts were that i had two options, either get out the ol' tap and dye set and add some threads or put washers on the end to keep things tight, then i realized that one of the left over sleeves worked perfectly...but...[IMG]
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When i went to test fit the TB the TB shaft was way too long and hit the hard coolant lines coming off of the thermostat housing. Bend that line in a lil' bit? Hell no! So, really pissed off at this point i took a step back and decided to cut the shaft down to the right length and rethread it.
Now what's nice about this is that you can cut any pitch thread you want and find the jam nut to match it, I believe I ended up going with a 8mmx1.25 dye and threading it down just a little farther than i needed to to make sure that things would tighten up all the way.
I did this at work and didn't have the camera with me...sorry
Now you'll notice that the DE TB's coolant nipples face a little different than the bluebird's[IMG]
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So...yes there's more work.
I took a trip to the local hardware store and got a couple 1/4" nipples barbed on both ends, some 1/4" hose clamps, and some 1/4" hose. I ended up clamping the barbs in the existing hoses and putting my new hose on them to lengthen the hoses to fit the new TB. I went with braided 1/4" hose just because i thought it would be nice to see the coolant flowing through them. Once these are lengthened go ahead and bolt the TB up to the Intake manifold and then worry about putting the hoses on the same way they were when you started. Now if you'll take your finger and put it in the TB where the TB and manifold meet you'll notice that it's a perfect match made in nissan heaven. Enjoy that throttle response, you'll be able to tell the difference just by playing with the butterly. More power? I couldn't tell you yet. The manifold does match the TB now, but my intercooler piping is only 2.5" also, so i doubt that i will see any big gains, as you will read in the thread posted at the top of this write up.
But I will post my set up along with #'s when i get them.
