grinding throttle stop- question on voltage?
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You're not really trying to acheive a specific voltage, you are trying to get the TB butterfly to a 90* angle at WOT. It's true that once you hit 4.75V (at least on a 2000 per the Helms manual) you will throw a code. I started out w/4.36V at WOT and ended with 4.60V. Results will vary some between TBs. Remember if you are using a scanner to check voltage it may only show voltage increments in 0.1V. I used a voltmeter when I did mine, but not strictly necessary.
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I just connected to my car(stock) with EFILive for the first time and it showed my throttle open 100%. I thought this was impossible with an untouched TB or does EFILive show 100% above a certain voltage?
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The Helm manual says the TB DTC goes set at 4.65 VDC WOT so you need to stop at no more than 4.64 VDC. You can grind till you get close to this number then bend the throttle cam tab to fine tune it. Grind a little at a time and check your voltage reading often. Bending the tab a couple of thousandths either way changes the voltage reading by a couple of tenths of a volt DC once you get the voltage close by grinding the bump stop. It also says it should be "NEAR" 0.6 VDC at closed throttle (idle). Adjust the torx screw to get the idle voltage reading you want. You should use a Digital VOM to get this kind of accuracy because they read down to the hundredth of a volt.