Throttle Valve Cable/Linkage: Service and Repair

Removal





1 Start by removing the valve body cover and then the valve body.

2 Detach the kick-down cable from the throttle arm and the holder.

Cars with TCS
The kick-down cable is detached from the KDW motor and the holder.

3 Unhook the cable from the throttle cam.

4 Remove the attachment part of the kick-down cable using an 11 mm jointed spanner.

5 Detach the clip by undoing the screw. (Use TORX TX27 spanner).

6 Remove the throttle cam, shaft and spring as a complete unit.

Fitting





1 Fit the throttle cam with shaft, hook in the spring as illustrated.

2 Fit the complete unit.

3 Fit the clip and tighten with a screw. (Screw size = TORX TX 27)

Tightening torque: 10 Nm (7.3 lbf ft)

4 Apply grease (vaseline) to the kick-down cable O-ring and push in the kick-down cable to its stop in the housing.

5 Tension the throttle cam one turn against spring force and hook on the kick-down cable nipple.

6 Fit the valve body (10 screws, TORX 27). There are three different lengths of screw.

Tightening torque: 10 Nm (5.8 lbf ft)

Note: If the original kick-down cable has been replaced with a new one, the stop on the kick-down cable should be crimped on 2.O-2.5 mm from the cable casing. The kick-down cable should not be under any load.

7 Fit the valve body cover, 4 screws, 10 mm.

8 Adjust the kick-down cable. Adjustments