Kick-Down Wire (KDW)

Kick-Down Wire (KDW)





To remove
1 Disconnect the battery cables and remove the battery.
2 Remove the ABS control unit and remove the connectors from the battery tray.
3 Remove the battery cable retaining clamps and disconnect the cables from the terminal block.
4 Lift out the relay and fuse board.
5 Remove the four retaining bolts and lift out the battery tray.




6 Clean the area round the kick-Down Wire, paying particular attention to the area where it is connected to the transmission.
7 Unplug the air mass meter's connector and move it aside.
8 Remove the dipstick from the automatic transmission.
9 Remove the four retaining bolts and remove the valve body cover from the transmission gearcase.
10 Move the selector lever to engage position "1".




11 Remove the oil pipe from the valve body (turbo), using tool 8791360.Note the O-rings.
12 Remove the valve body.




13 Remove the retaining clip and disconnect the wire from the lever of the KDW motor.
14 Remove the nut for the holder securing the wire and sheathing to the actuator motor bracket.
15 Release the wire and sheathing from the holder by first pulling it upwards out of the holder and then loosening it at the bottom.
16 Lift the wire off the throttle cam, free the end nipple and remove the wire and sheathing from the gear casing.
Note the rubber seal on the wire sheathing connection to the gear casing.




To fit
1 Smear the O-ring for the wire sheathing with grease and fit the wire and sheathing to the transmission gear casing.
2 Secure the nipple on the end of the wire to the throttle cam and fit the wire in the groove in the cam.
3 Fit the wire sheathing in the holder by fastening it at the bottom and then moving it downwards from above.
4 Secure the wire and sheathing to the motor bracket without tightening the nut.
5 Connect the wire to the lever of the motor and fit the retaining clip.




6 Insert the gear selector slide all the way into the valve body (corresponding to position "1" on the selector lever).
7 Fit the valve body in place.See illustration for position of bolts.
Tightening torque: 7-9 Nm (5.1-6.6 lbf ft)
8 Check the condition of the 0-rings and replace as necessary.Fit the oil pipe to the valve body using special tool 8791782.




9 Clean the contact surfaces of the valve body cover.
10 Clean the contact surfaces of the gear casing and fit a new gasket on the valve body cover. Hold the turbo pressure pipe aside when tightening one of the four bolts.
Tightening torque: 6 Nm (4.4 lbf ft)
11 Put the oil dipstick back in the gear casing and plug in the air mass meter's connector.




12 Make sure that the lever is in the fully "withdrawn position" against the stop (rest position without wire).This position must be maintained for points 13 and 14.
13 Pull the Kick-Down Wire's sheathing past the Kick-Down position to the stop in the gear casing.
14 Fix the wire sheathing to the holder on the motor bracket.Note that the length of withdrawn wire must be maintained unchanged.




15 Fit the battery tray in place, connect the cables to the terminal block and refit the battery cable clamps.
16 Fit the ABS control unit in position and also the relay and fuse board.
Cars with DI: Fit the three connectors in place on the battery tray.
17 Refit the battery and connect the battery cables.
18 Use an ISAT instrument to calibrate the KDW motor. Calibration of TCS
19 Check the work area when you have finished. Also check that the KDW works properly and carry out a general check for leaks.