1

ATB Feedback SensorUpgrade Kit

© 2015 Copyright All Rights ReservedATB Feedback Sensor Upgrade Kit 10.15 PIB 4170 A

Upgrade Kits that add throttle position feedback sensors to existing ATB assemblies are described.

1

3

2

INDEX

KT555 T1 SENSOR INSTALLATION PROCEDURE

KT555 - T1 SENSOR UPGRADE KIT CONTENTS

QTY Item Part Number

1 (A) Cover - Spring Cavity CV543

1 (B) Plate Assembly - Spring Return PLS557

1 (C) O-Ring Seal SE108-20X1.5FKM

2 (D) M4x.7x5mm Set Screws HW05-609

2(E) M4x.7x8mm ButtonHead Screw (T20) Drive

HW05-661

1 (F) Position Feedback Sensor SN289

1 (G) Connector Kit - Feedback Sensor EC1523

1. Remove the 8 screws and cover plate from the ATB assembly. Scrape off the Loctite 5999 found on the cover if present. Remove and discard gasket if present.

2. Prior to removing the spring and spring return plate, the Mininum Throttle Adjustment needs to be recalibrated to 0% fuel. To do so, back the Mini-mum Throttle Adjustment screw so that the shaft is allowed to rotate to the 0% fuel position (valve closed).

3. Hold the shaft/butterfly valve at 0% fuel while screwing the minimum fuel adjustment screw. The screw should barely make contact with the edge of the spring return plate.

4. Remove two extension springs from the pins on the spring stop plate (2).

5. Loosen two M4 set screws (4) and pull the spring return plate (2) off of the actuator shaft.

6. Push the spring return plate assembly (B), part number PLS557, onto the actuator shaft and rotate it counter-clockwise so the flat edge of the plate makes contact with the minimum adjustment screw. Then rotate the shaft /butterfly valve to the 0% fuel position.

7. Torque the two M4 set screws (4), coated with Loctite 603, to 18-20 in-lbs.

8. Connect the two extension springs to the spring pins, apply a small amount of Lithium grease onto the hook ends of each spring.

Spring Return Plate(B) Assembly P/N PLS557

D

G

A F

C

E

B

4 Set Screw

4 Set Screw2 Factory Spring

Return Plate

Extension Spring

Extension Spring

Min Throttle Adjustment

VIEW 1 ATB External

VIEW 2 Upgraded Spring Assembly On Shaft

9. Install the spring cavity cover, part number CV543, with eight M3 button head torx cap screws. Be sure to add Loctite 222 to the screw threads and Loctite 5999 on the sealing surface of CV543.

10. Place the O-ring seal into the seal groove of the spring cavity cover.

11. Supply the sensor with 5.0V. Monitor the output voltage while manually rotating the sensor blade to read 1.0V, prior to installing.

12. Install sensor, part number SN289, onto the cover positioning the radial location of the sensor blade to engage the slot in the end of the PLS557 when fully seated. Insert two sensor retaining M4 button head cap screws using Loctite 222.

13. Rotate the feedback sensor, with the throttle body in the no fuel position (0%) to set 1.0V output.

14. Torque the two sensor retaining screws coated with Loctite 222 to 12 - 15 in-lbs.

• T1 ATB: Kit number KT555, Page 1

• T2/T3 ATB: Kit Number KT552, Page 2,3

• T4 ATB: Kit Number KT556, Page 4

2

2X

21

4

5

17

12

10

9

11

8

7

6

16

3

15

2

2

18

1413

2X

2X3X

3X

2X

4X

3X20

TABLE 1:

NOITPIRCSED.ON TRAPYTQMETI1 2xxBTA DENIHCAM - GNISUOH2 ELBAT EES12 GNIRAEB LLAB2 ELBAT EES23 2T2xxBTA - TFAHS205HS14 2xxBTA ELTTORHT - ETALP2 ELBAT EES15 SS,MM8X7.X4M ,XROT ,DH NTB166-50WH26 MSA NIM/XAM ,GRPS 3 - ETALP125SLP17 Z,TP PUC MM5X7.X4M,HCS XEH,RCSS906-50WH28 TNEMTSUJDA GRPS 3 - ETALP905SLP19 Z,4M ,GRPS LCLH ,RHSW KL216-60WH3

10 Z,MM01X7.X4M,RCS PAC HCS606-50WH311 ETAR RWL BTA DEM NOISNETXE-GNIRPS705PS212 1 SE108-78X1.5FKM SEAL - O-RING 78X1.5MM, FKM13 REVOC2 ELBAT EES114 4 SEE TABLE 2 SHCS,M5X12, SS, DIN912 ROHS (HW05-654) OR SHCS,M5X16, SS, DIN912 ROHS (HW05-655)15 2T2xxBTA DENIHCAM - ERUTAMRA52-205TA116 Z,TP PUC,MM5X7.X5M,HCS XEH,RCSS806-50WH217 Z,TP PUC,MM02X7.X4M,HCS XEH,RCSS406-50WH218 TFAHS ,LAES511ES119 EVAW - GNIRPS203PS120 4M ,REHSAW TALF416-60WH321 Z,MM4X7.X4M,GNIR-O NOTIV,DHSRC,DHNP807-50WH2

2X2X

19

© 2015 Copyright All Rights Reserved

ATB Feedback Sensor Upgrade Kit 10.15 PIB 4170 A

4 KT552 - T2/T3 SENSOR UPGRADE KIT CONTENTS

QTY Item Part Number

1 (A) Plate - 3 Spring, max/min Assembly with FB

PLS522

2 (B) M4x.7x5mm Set Screw HW05-609

1 (C) O-Ring Seal SE108-78X1.5FKM

1 (D) Cover, ATB, AB Sensor, Sealed, 0.250” CV609-2

4 (E) M5x.8x16mm Socket Head Cap Screw HW05-655

1 (F) O-Ring Seal SE104-115FKM

1 (G) Plate - AB Adapter PL219

2 (H) M4x.7x16mm Button Head Screw HW05-653

1 (I) 5/32” x 1/2” Dowel Pin HW08-809-013

1 (J) Plate - Sensor Adapter PL189

1 (K) M4x.7x8mm Set Screw HW05-576

1 (L) O-Ring Seal SE104-022V

1 (M) Position Feedback Sensor SN275-1

2 (N) M4x.7x35mm Button Head Cap Screw HW05-597

1 (O) Mating Connector Kit - Feedback Sensor EC1515

KT552 - T2/T3 DISSASSEMBLY 5

1. Remove cover plate (13).

2. Prior to removing the extension springs (11), adjusting plate (8), and max/min adjusting plate(6), the Mininum Throttle Ad-justment needs to be recalibrated to 0% fuel. To do so, back the Minimum Throttle Adjustment screw out so that the shaft is allowed to rotate to the 0% fuel position (valve closed).

3. Hold the shaft/butterfly valve at 0% fuel while screwing the minimum fuel adjustment screw into the ATB so that the end of it barely touches the edge of the spring return plate.

4. Remove the extension springs (11), adjusting plate (8) and max/min adjusting plate (6).

5. Retain wave washer (19), 3 M4 socket head cap screw (10) 3 M4 lock washers (9) and 3 M4 flat washers (20) for reuse.

6. Clean and inspect the extension springs (11) and adjusting plate (8) for reuse.

Spring Adjusting Plate (8)

Min Throttle Adjustment

A

B

C

E

O

N

M

L

H

G

F

IJK

D

Retain the Wave Washer (19)

PROCEDURE

3 Spring Max/Min Plate Assembly (6) Retained With Two M4x.7x35mm Set Screws

3

30

25

23

3

4

5

26

7

6

8

9

10

11

12

13 14

15

16

19

17

18

20

22

24

2X

2

2

21

27

2X

2X

2X 2X

2X

3X

3X

3X 2X

28

4X

2X

29

TABLE 1:

8 7

ITEM QTY PART NO. DESCRIPTION1 1 SEE TABLE 2 HOUSING - MACHINED ATBxx22 2 SEE TABLE 2 BALL BEARING3 2T2xxBTA - TFAHS205HS14 1 SEE TABLE 2 PLATE - THROTTLE ATBxx25 2 HW05-661 BTN HD, TORX,M4X.7X8MM,SS6 1 PLS522 PLATE - 3 SPRG, MAX/MIN ASM W/FB 7 2 HW05-609 SSCR,HEX SCH,M4X.7X5MM CUP PT,Z8 1 PLS509 PLATE - 3 SPRG ADJUSTMENT9 3 HW06-612 LK WSHR, HLCL SPRG, M4,Z

10 3 HW05-606 SCH CAP SCR,M4X.7X10MM,Z11 2 SP507 SPRING-EXTENSION MED ATB LWR RATE 12 1 SE108-78X1.5FKM SEAL - O-RING13 1 CV609-2 COVER, ATB, AB SENSOR, SEALED, .25"14 4 HW05-655 SHCS,M5X.8X16,SS, DIN912 ROHS15 1 SE104-115FKM SEAL - O-RING16 1 PL219 PLATE - AB ADAPTOR17 2 HW05-653 BTN HD, HEX SCH,M4X.7X16MM,SS,ISO738018 1 HW08-809-013 PIN - DOWEL H&G STANDARD 5/32X1/219 1 PL189 PLATE - SENSOR ADAPTOR20 1 HW05-576 SSCR,HEX SCH,M4X.7X8MM,CP,Z21 1 SE104-022V SEAL - O-RING22 1 SN275-1 SENSOR - FEEDBACK23 2 HW05-597 BTN HD, HEX SCH,M4X.7X35MM,Z24 1 AT502-25 ARMATURE-ATBXX2, 1.000" MACHINED25 2 HW05-608 SSCR,HEX SCH,M5X.8X5MM CUP PT,Z26 2 HW05-604 SSCR,HEX SCH,M4X.7X20MM,CUP PT,Z27 TFAHS ,LAES511ES128 EVAW - GNIRPS203PS129 3 HW06-614 FLAT WASHER, M430 2 HW05-708 PNHD,CRSHD,VITON O-RING,M4X.7X4MM,Z

N

ML

15J

I

KHF

G

EDC

A

B

ATB Feedback Sensor Upgrade Kit 10.15 PIB 4170 A

© 2015 Copyright All Rights Reserved

KT552 - T2/T3 SENSOR INSTALLATION PROCEDURE6

Spring PlatePLS522

Min Throttle Adjustment

Shaft

Min Throttle Adjustment makes contact with the flat edge of the spring plate

Remove screws when adjusting the Min and Max Throttle Screws

1. Install max/min spring plate assembly, with Feedback Sensor, (A) onto the actuator shaft and rotate it toward the minimum throttle adjustment screw so the flat edge of the plate makes contact with the screw. Then rotate the shaft/butterfly valve to the 0% fuel position (closed). See Pictures Below

2. The spring plate assembly should be positioned so the wave washer’s pre-load height is 0.020” from full compression.

3. Apply Loctite 603 to two M4x.7x5mm max/min spring plate assembly re-taining set screws (B), torque to 18 - 20 in-lbs.

4. Install the spring adjusting plate (8) with three M4x.7x10mm socket head cap screws (10), Lock washers (9) and flat washers (29).

5. Connect three extension springs (11) with one end on the adjusting plate post (8), the other on the max/min spring plate post (6) so the spring force loads the throttle plate in the closed direction. Apply a small amount of general purpose Lithium grease to the hook ends of each spring.

6. Rotate the spring adjusting plate (8) so the throttle plate lifts-off at 16-18 oz-in. Torque the three adjusting plate retaining screws (10) to 18-20 in-lbs.

7. Lubricate the housing O-ring seal (C) with an all purpose Lithium grease and place it in the O-ring groove.

8. Mount the ATB sensor cover plate (D) onto the housing, install four M5 socket head cap screws (E), coat the threads with Loctite 222 and torque to 33-35 in-lbs.

9. Install O-ring seal (F) onto the AB adapter plate (G) and coat it with Lithium grease, insert the adapter plate into the cover plate (D) and insert two M4 button head retaining screws (H), coat the threads with Loctite 222. Do not tighten.

10. Install the O-ring (L) onto the feedback sensor (M) and lubricate the entire seal with Lithium grease.

11. Press the 5/32 x 1/2” dowel pin (I), coated with Loctite 603, into the sensor adapter plate (J).

12. Insert the M4x.7x8mm set screw (K) into the sensor adapter plate (J), coat the threads with Loctite 222.

13. Place the sensor adapter plate (J) onto the feedback sensor (M) with the adapter plate oriented so the set screw is seated on the flat, torque to 20 - 25 in-lbs.

14. Insert the sensor and adapter plate assembly into AB adapter plate (G) positioning the dowel pin so it engages the spring loaded coupling on max/min plate assembly (A). Coat the threads of two M4x.7x35mm button head cap screws (N) with Loctite 222 and torque to 20 - 25 in-lbs.

15. Supply the feedback sensor with 5.0V. Monitor the output voltage and man-ually rotate the position feedback sensor with the throttle body in the no fuel position (0%) set to1.0V output. Maximun output, at 65° throttle body rotation (100%) should be approximately 3.8V. Torque the two sensor re-taining screws (H) to 20 - 25 in-lbs.

VIEW 1 ATB External

VIEW 2 Housing has been removed for internal persepctive

4ATB Feedback Sensor Upgrade Kit 10.15 PIB 4170 A

© 2015 Copyright All Rights Reserved

KT556 - T4 SENSOR INSTALLATION PROCEDURE 7T4 Series ATB’s are configured to accept feedback sensor part number SN288. Upgrade kit KT556 includes the SN288 sensor and its mating connector EC1523.

Sensor Part No. SN288

QTY Item Part Number

1 (A) Position Feedback Sensor SN288

1 (B) Mating Connector EC1523

A B

HARNESS

PIN SIGNAL

A +5V

B GND

C OUT

Mating ConnectorEC1523

A B C

Sensor Cover Plate

1. Remove two screws (14) and the feedback sensor cover plate (7).

2. Supply the sensor with 5.0V. Monitor the output voltage and manually rotate the sensor blade until the output voltage reads 1.0V. Insert the sensor so its blade engages the slot in the end of the actuator shaft, with the throttle plate in the no fuel position (0%). Apply Loctite 222 to the two screws (14) and insert them. Do not tighten.

3. Rotate the feedback sensor, with the throttle body in the no fuel position (0%) to set a 1.0V output. Torque the two sensor retaining screws (14) to 12 - 15 in-lbs.