Throttle Control Actuator: Service and Repair

Removal
1 Remove the engine covers.
2 Disconnect the control rod from the throttle.
3 Release the bracket fastenings.
4 Remove the control plate bracket.
5 Undo the hose clamp securing the mass air flow sensor to the resonator box.
6 Open the two snap locks between the mass air flow sensor and the air cleaner.
7 Unplug the connectors and remove the mass air flow sensor.
8 Remove the idle air control valve hose on the inlet manifold.
9 Undo the hose clamps between the inlet manifold and the throttle body.
10 Lift the intake manifold complete with resonance box.
- Remove the two vacuum hoses from the vacuum tank and the outer throttle control valve as well as the electrical connectors for the control valve.
11 Remove the intake manifold and the resonance box.





12 Remove the four nuts securing the main throttle and the Traction Control System (TCS) throttle.
- Pull out the main throttle and disconnect the hoses.
13 Disconnect the crankcase ventilation hoses.
14 Unplug the throttle body connectors and care fully lift the vacuum plate,
15 Lift away the throttle body.

Installation





1 Clean all contact surfaces between the main throttle body, TCS throttle body and the intake manifold, and clean the surfaces on the intake manifold parting line.
2 Check the 0-rings in the TCS throttle and lubricate with a little Vaseline.
- Fit the TCS throttle in place and plug in the connector.
3 Connect the hose to the crankcase ventilation.
4 Check the 0-rings in the throttle body.
- Check both 0-rings for the vacuum plate and the mating surface. Lubricate with a little Vaseline.
5 Fit the throttle body in place, attach the cable conduit and tighten the nuts to: 8 Nm (6 ft lb)

6 Connect all hoses to the throttle body.
7 Fit the intake manifold and the resonance box and all other parts that have been removed.

Important After fitting, check/adjust the throttle cable and the kick-down cable (where fitted) using special tool part No. 87 92 459, refer to Powertrain Management.

8 Fit the engine covers.
9 Test drive and check the TCS is working properly.