Throttle Valve Cable/Linkage: Service and Repair

NOTE: Component identifier numbers used in the following illustrations relate to specific steps in the procedures below.





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.

NOTE: Cars With Traction Control System (TCS) The kick-down cable is detached from the Kickdown Cable Motor (KDW motor) and the holder.

3. Unhook the cable from the throttle cam.
4. Remove the attachment part of the kick-down cable using a suitable 11 jointed wrench.
5. Use a Torx TX27 wrench and detach the clip by undoing the screw.
6. Remove the throttle cam, shaft and spring as a complete unit.





Installation
1. Install the throttle cam with shaft, hook in the spring as illustrated.
2. Install the complete unit.
3. Install the clip and tighten with a screw.
- Screw size = TORX TX 27
Tightening torque: 10 Nm (6.3-7.7 ft. lbs.)
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. Valve body (10 screws, TORX 27).
- There are three different lengths of screw, refer to the illustration.
- Tightening torque: 10 Nm (7.3 ft. lbs.)

NOTE: If the original kick-down cable has been replaced with a new one, the stop on the kickdown cable should be crimped on 2.0-2.5 mm from the cable casing.
- The kick-down cable should not be under any load.

7. Install the valve body cover with the four 10 mm screws.
8. Adjust the kick-down cable.