ATB Feedback Sensor

Upgrade Kit
1
6. Push the spring return plate assembly (B), part number PLS557, onto the
INDEX 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 /
Upgrade Kits that add throttle T1 ATB: Kit number KT555, Page 1
position feedback sensors to butterfly valve to the 0% fuel position.
T2/T3 ATB: Kit Number KT552, Page 2,3
existing ATB assemblies are 7. Torque the two M4 set screws (4), coated with Loctite 603, to 18-20 in-lbs.
described. T4 ATB: Kit Number KT556, Page 4
8. Connect the two extension springs to the spring pins, apply a small amount
2 KT555 - T1 SENSOR UPGRADE KIT CONTENTS of Lithium grease onto the hook ends of each spring.

VIEW 1 ATB External

G

A F

D
C
B

Min Throttle
Adjustment
E Spring Return Plate
(B) Assembly P/N PLS557

QTY Item Part Number VIEW 2 Upgraded Spring Assembly On Shaft

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
(E) M4x.7x8mm Button
2 HW05-661
Head Screw (T20) Drive
1 (F) Position Feedback Sensor SN289
1 (G) Connector Kit - Feedback Sensor EC1523

3 KT555 T1 SENSOR INSTALLATION PROCEDURE

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.
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.

Extension Spring 4 Set Screw 14. Torque the two sensor retaining screws coated with Loctite 222 to 12 - 15
in-lbs.

2 Factory Spring
Extension Spring
Return Plate 4 Set Screw ATB Feedback Sensor Upgrade Kit 10.15 PIB 4170 A
1 2015 Copyright All Rights Reserved
 4 KT552 - T2/T3 SENSOR UPGRADE KIT CONTENTS

QTY Item Part Number

F
L 1 (A) Plate - 3 Spring, max/min
PLS522
Assembly with FB
C
2 (B) M4x.7x5mm Set Screw HW05-609
1 (C) O-Ring Seal SE108-78X1.5FKM
G J M 1 (D) Cover, ATB, AB Sensor, Sealed, 0.250 CV609-2
A I K 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
B 1 (J) Plate - Sensor Adapter PL189
1 (K) M4x.7x8mm Set Screw HW05-576
1 (L) O-Ring Seal SE104-022V
E D H
N 1 (M) Position Feedback Sensor SN275-1
2 (N) M4x.7x35mm Button Head Cap Screw HW05-597
O
1 (O) Mating Connector Kit - Feedback Sensor EC1515

5 KT552 - T2/T3 DISSASSEMBLY

PROCEDURE
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.
Min Throttle Adjustment
6. Clean and inspect
5 2X
the extension springs (11) and adjusting
plate (8) for reuse.
Spring Adjusting Plate (8)
4 3 Spring Max/Min Plate Assembly (6)
Retained With Two M4x.7x35mm Set Screws

17 2X 21 2X

18

20 3X
7 2X
19 9 3X
2
8 10 3X

11 2X
12 13
14 4X

Retain the Wave Washer (19)

ATB Feedback Sensor Upgrade Kit 10.15 PIB 4170 A

2 2015 Copyright All Rights Reserved
 2X 5

6 KT552
4
- T2/T3 SENSOR INSTALLATION PROCEDURE

2X 26 2X 30

27

28 29 3X

B
7 2X 8

9 3X 11 2X

10 3X
C
12

D
13
E
14 4X

G
16
I
18

15
A6 J
19
L
15

M
22

N
23 2X

1. Install max/min spring plate assembly, with Feedback Sensor, (A) onto the
actuator shaft and rotate it toward the minimum throttle adjustment screw F21
so the flat edge of the plate makes contact with the screw. Then rotate the K
shaft/butterfly valve to the 0% fuel position (closed). See Pictures Below H
17 2X 20

2. The spring plate assembly should be positioned so the wave washers pre-
load height is 0.020 from full compression.
3. Apply Loctite 603 to two M4x.7x5mm max/min spring plate assembly re-
VIEW 1 ATB External 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.
Spring Plate
PLS522
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.

Min Throttle Adjustment 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
VIEW 2 Housing has been removed for internal persepctive 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
Remove screws the threads with Loctite 222.
when adjusting
Shaft 13. Place the sensor adapter plate (J) onto the feedback sensor (M) with the
the Min and Max
Throttle Screws 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 Throttle Adjustment min plate assembly (A). Coat the threads of two M4x.7x35mm button head
makes contact with the flat cap screws (N) with Loctite 222 and torque to 20 - 25 in-lbs.
edge of the spring plate
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.

ATB Feedback Sensor Upgrade Kit 10.15 PIB 4170 A

3 2015 Copyright All Rights Reserved
 7 KT556 - T4 SENSOR INSTALLATION PROCEDURE
T4 Series ATBs are configured to accept feedback sensor part number SN288.
Upgrade kit KT556 includes the SN288 sensor and its mating connector
EC1523.

QTY Item Part Number

1 (A) Position Feedback Sensor SN288
1 (B) Mating Connector EC1523

A B
Mating Connector
Sensor Part EC1523
No. SN288
HARNESS
PIN SIGNAL
A +5V

A B C B GND
C OUT

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.

ATB Feedback Sensor Upgrade Kit 10.15 PIB 4170 A

4 2015 Copyright All Rights Reserved