Grand Prix LS1 Intercooler - Contents Under Pressure

Using the top piece of the intercooler core housing as a template, we trimmed the other supplied intake manifold gasket to fit it.

Once again using our trusty RTV, we ran a bead around the area of the gasket that we cut off, including the new PCV channel and installed the top half of the intercooler housing and the freshly trimmed gasket on top of it.

We then set the supercharger on top of the new intercooler and using the supplied bolts and lock washers, secured the whole assembly to the engine and torqued it to spec (this may require making a tool using another Allen wrench in some cases).

While the sealant dried on the intercooler and WPI supercharger, it was the perfect time to install the LS1 Throttle Body Conversion Kit. The first thing we did was get the wiring harness that runs over the supercharger back on top of the supercharger. Next we removed the original throttle body mounting studs and set them aside, and removed the throttle body locator pin (a pair of pliers or wire cutters works well here).

Using the same RTV that we used so many times before, we applied a liberal amount to the back of the LS1 Throttle Body adapter plate and attached it to the supercharger using the supplied Allen head screws. (Note the RTV bulging out between the plate and the supercharger; it's a good idea to let it dry at this point and then remove the excess.)

After removing the excess RTV from inside the inlet, we screwed our original throttle body studs into the LS1 adapter plate.

We carefully but liberally coated the back side of the LS1 throttle body with our new best friend, you guessed it, RTV (sounds like a Permatex commercial, eh?).

Then we installed the LS1 throttle body onto the studs and secured it with the original throttle body retainer nuts. Next, we attached the vacuum hose to the port on the top and reconnected the TPS and IAC harness (the IAC harness on some GTPs may need to be extended depending on the year of your Pontiac.) The supplied throttle cable bracket and throttle and cruise control cables as well as the included air bellows to the LS1 Throttle Body and the LS6 MAF sensor to the bellows were all installed. Finally, we attached the MINI-AFC to the LS6 MAF and our original MAF harness.

We set the MINI-AFC to 100 percent as shown here by using the supplied instructions. (The unit is programmed by binary addition so it may take a few seconds to realize how to program it.) This device will let you pinpoint your fueling later but for the sake of quick installation 100 percent works for now.