Throttle body coolant bypass mods

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The throttle body coolant passage seems to be a problem area for some guys looking to swap a LSx in their cars.

The throttle body coolant crossover is designed to maintain a warm throttle body temperature in cold weather. Humid, sub-freezing air entering the throttle body can cause ice buildup on the throttle blade and result in abnormal air turbulence into the intake and could possibly not allow the throttle blade to fully close. The benefits of eliminating the crossover is a small performance gain and a cleaner install. For most of you swappers, cold weather performance is not a big factor, so this system can be eliminated.

Factory applications return the spent coolant to the radiator, most of us do not use the donor radiator so something has to be done. There are several ways of eliminating the crossover:

The first, and probably the simplest, is to insert a special "Tee" fitting into the upper radiator hose. This method connects the crossover directly to the upper radiator hose, returning all flow to the upper hose. The downside to this installation is eye appeal, generally it sits in plain sight and can be an eyesore. This fitting can be purchased from several suppliers or made at home.

The second, and most popular, is to drill and tap the "other port" casting pad on your water pump for a 90" hose barb fitting. By the "other port" I mean the pad area where the upper radiator hose outlet port could be cast in. For LS series this is on top, for truck motors it is in front. You simply drill and tap a hole for a 90* elbow and attach the hose there.
http://img19.imageshack.us/img19/3186/dscn2329.jpg
http://img151.imageshack.us/img151/3406/dscn2331.jpg
Alternate location for fitting placement.
http://img11.imageshack.us/img11/8452/photo46x.jpg
Photo courtesy of Andrew Borodin; http://www.pro-touring.com/forum/sho...003#post369003

A third way is defiantly the cleanest, but is only practical on truck motors and could be potentially pricey, depending on who you know. This method includes using a second coolant crossover tube as a donor for the hose barb. remove the barb and drill the water neck of the water pump. Weld the bard to the water neck in a fashion that allows a straight shot for the hose to enter the water neck.
http://img523.imageshack.us/img523/5845/dscn2397g.jpg
http://img14.imageshack.us/img14/7218/dscn2399o.jpg
*Pics represent a Magnacharger application, but can be used with the
standard intakes.

Another method is to drill and tap the thermostat housing for a hose barb fitting.
http://img27.imageshack.us/img27/2448/photo082508001.jpg
http://img261.imageshack.us/img261/6088/photo082508002.jpg

All pictures used with permission of the owners.

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