Part # GM LS2, 3 & 7-95mm Throttle Body

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1 Part # GM LS2, 3 & 7-95mm Throttle Body Perfect Performance Products, LLC 2501 Ludelle St. Fort Worth, Texas (800)

2 We are always concerned about any corrections or improvements that can be made to these instructions. If you have found any errors, omissions or you simply have comments or suggestions concerning these instructions, please write us at the address on the cover and let us know about them. Or, better yet, send us a fax at (817) For Technical Questions address: Tech Line: (800) Hours: 8am-5pm CST Monday-Friday Perfect Performance Products, Inc. shall in no event be liable in contract or tort (including negligence) for special, indirect, incidental or consequential damages, such as, but not limited to, loss of property damage, or any other damages, such as, cost or expenses which might be claimed as the result of the use or failure of the goods sold herby, except only the cost of repair or replacement. September 2011 Copyright 2011 by Perfect Performance Products, LLC. 2

3 1.0 INTRODUCTION Please read all instructions prior to install. Use these instructions as a guide to install the PERFECT HI VELOCITY THROTTLE BODY onto your GM LS2, 3 or 7 engines. NOTICE: This Throttle Body will not work on a GM LS2, 3, or 7 unless an aftermarket Engine Management System is used. The factory GM computers used to run these engines are for Throttle-by-Wire or Electronic Throttle Body s ONLY and will not have the functionality needed to run the LS1 IAC(Idle Air Control Motor) or LS1 TPS(Throttle Position Sensor). 2.0 TOOLS AND PARTS NEEDED FOR INSTALLATION You will at least need the following tools: Allen wrenches or allen sockets: 5mm, 5/32, 9/64 and 3/32 (These will fit all of the new stainless fasteners included with this kit) Flat screwdriver (To install and tighten hose clamps on silicone coupling) Ratchet, 3 extension, 10mm shallow socket (Used to remove original throttle body bolts) 3.0 STEP-BY-STEP INSTALLATION 3.1 Remove original electronic throttle body from the LS2, 3 or 7 intake manifold using the ratchet, 3 extension and 10mm socket. See Figures 3-1 & 3-2. Figure 3-1 Removal of the original electronic throttle body bolts. 3

4 Figure 3-2 Removal of the original electronic throttle body. 3.2 Carefully inspect the molded silicone gasket on the intake manifold throttle body gasket surface. If it is damaged or torn replace it with a new one. See Figure 3-3. Figure 3-3 Molded Silicone Gasket 4

5 3.3 Installation of the Throttle Position Sensor (TPS) on the new throttle body. The TPS used is the same sensor that can be found on a 2000 Chevrolet Camaro/Pontiac Firebird with an LS1. The GM part number is The alignment pin on the back side of the sensor must be removed in order for it to fit the new throttle body. See Figures 3-4 thru 3-6 for both illustration and instruction on how to install the Throttle Position Sensor correctly. Figure 3-4 Removal of the alignment pin on the Throttle Position Sensor 5

6 Figure 3-5 Throttle Position Sensor 6

7 Figure 3-6 Carefully tighten the provided stainless socket head cap screws for the Throttle Position Sensor using a 5/32 Allen wrench. Notice: The Throttle Position Sensor is adjustable once installed on the new throttle body. The throttle body was designed this way to allow for a fully adaptable Throttle Position Sensor signal no matter what aftermarket fuel injection system is being used to run your LS2, 3 or 7. Simply loosen the screws installed in Figure 3-6 and carefully turn the sensor clockwise or counter clockwise to achieve the required idle and wide open throttle (WOT) voltages. DO NOT OVERTIGHTEN THE BOLTS FOR THE THROTTLE POSITION SENSOR!!! BE CAREFULL!!! 7

8 3.4 The IAC motor used is the same as a 2000 Chevrolet Camaro/Pontiac Firebird with an LS1. The GM part number is The o-ring on the IAC motor must be intact and the correct size. Carefully align the pintle on the IAC with the small hole on top of the throttle body. Using the provided 8-32 socket head cap screws, fasten the motor to the new throttle body. See Figures 3-7 & 3-8 for more details. Figure 3-7 Idle Air Control (IAC) Motor Check O-ring and Install 8

9 Figure 3-8 Idle Air Control (IAC) Motor Tightening 8-32 Stainless Screws DO NOT OVERTIGHTEN THE BOLTS FOR THE IDLE AIR CONTROL MOTOR!!! BE CAREFULL!!! See Figure 3-9 page 10 for the properly installed TPS and IAC motor. 9

10 Figure 3-9 TPS and IAC motor installed 10

11 3.5 Before installing the throttle body on the intake manifold it will be necessary to carefully bend the Coolant Air Bleed Pipe to clear the throttle linkage. The bend needed on the pipe outlet can be seen below in Figures 4-1 & 4-2. Figure 4-1 Coolant Air Bleed Pipe STOCK Position Figure 4-2 Coolant Air Bleed Pipe MODIFIED Position 11

12 3.6 Installing the throttle body on to the intake manifold with the four provided socket head cap screw bolts. This requires a 5mm allen wrench and must only be carefully tightened in a cross pattern until they are snug OR preferably torqued to 10 N.m. / 89 lb in with a torque wrench and a 5mm allen socket. See Figure 4-3. Figure 4-3 Installation of the (4) four throttle body bolts. DO NOT OVERTIGHTEN THE BOLTS FOR THE THROTTLE BODY!!! IT IS POSSIBLE TO STRIP THE THREADS OUT OF THE BRASS INSERTS ON THE INTAKE MANIFOLD. BE CAREFULL!!! 12

13 3.7 Be sure to double check the Coolant Air Bleed Pipe clears the throttle body throttle horn. With the engine OFF, move the throttle through its entire range to WOT (Wide Open Throttle) to check for any clearance issues. It s best to have at least 1/2 gap between them as shown in Figure 4-4. Figure 4-4 Notice the clearance between the pipe and the throttle horn. KEEP IN MIND THIS PIPE WILL HAVE A 3/16 COOLANT HOSE CONNECTED FROM IT TO THE UPPER RADIATOR HOSE. BE SURE YOU HAVE ENOUGH CLEARANCE BETWEEN THE THROTTLE HORN AND THE HOSE AND HOSE CLAMP. 13

14 3.8 Depending on the type of air filter and intake pipe configuration being used on your vehicle will determine how the included 4 inside diameter silicone coupling and clamps will be used. When installing the coupling it is necessary to spray a small amount of WD-40 spray around the inside of the coupling. This will aid in slightly stretching it over the outside of the throttle body opening. Once the coupling is fully pushed onto the throttle body, securely hold it in place with the provided hose clamps. See Figure Install the throttle cable bracket with the provided ¼ -28 socket head cap screws using a 3/16 allen wrench. Notice the bracket must be aligned with the throttle horn in order for the cable to function properly. See Figures 4-4, 4-6, 4-7 & 4-8. Figure 4-5 Notice the silicone coupler is pushed on all the way. 14

15 3.10 Attach the Throttle Cable Adjuster ( LOKAR example shown) to the throttle cable bracket. See Figure 4-6. Figure 4-6 Throttle Cable Adjuster 15

16 3.11 Next insert the throttle cable and throttle cable housing into the throttle cable adjuster. See Figure 4-7. Figure 4-7 Throttle Cable and Throttle Cable Housing 16

17 3.12 Once the throttle cable is inserted through the brass cable end tighten the set screw with a 3/32 Allen wrench. See Figure 4-8. Figure 4-8 Brass Cable End Set Screw 17

18 Painless Performance Limited Warranty and Return Policy Chassis harnesses, fuel injection harnesses and Striker are covered under a lifetime warranty. All other products manufactured and/or sold by Painless Performance are warranted to the original purchaser to be free from defects in material and workmanship under normal use. Painless Performance will repair or replace defective products without charge during the first 12 months from the purchase date. No products will be considered for warranty without a copy of the purchase receipt showing the sellers name, address and date of purchase. You must return the product to the dealer you purchased it from to initiate warranty procedures. Copyright 2011 by Perfect Performance Products, LLC 18

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