Attachment III - Technical Information

OVERVIEW

In some of the affected vehicles, there may be inadequate clearance between the engine cover and the speed control cable, which could allow the throttle to stick when the accelerator pedal is fully or almost-
fully depressed, increasing the risk of an accident.

Dealers are to install a revised rear stud and grommet assembly, and also trim the engine cover using a rotary burr type tool.

ENGINE COVER MODIFICATION





1. Remove the three nuts and the engine cover. See Figure 1.

2. NOTICE: Do not bend the speed control cable. The throttle cable bracket must be positioned aside or damage to the speed control cable may occur.

Check to see if the speed control cable has been previously disconnected.

^ If the speed control cable is connected, proceed to step 3.





^ If the cable is disconnected, reconnect the speed control cable to the throttle body before proceeding to step 3. See Figure 2. To reconnect the cable:

a. Loosen the RH throttle cable bracket bolt and remove the LH cable bracket bolt.

b. Rotate the bracket to allow enough clearance for the speed control cable to be removed.

c. Remove the speed control cable from under the bracket and connect the cable to the throttle body.

d. Reposition the throttle cable bracket and tighten both bracket bolts to 10 Nm (89 lb-in).





3. Remove the original rear stud and grommet assembly from the LH valve cover and install the new stud and grommet assembly. See Figure 3.

^ Tighten the new stud and grommet assembly to 10 Nm (89 lb-in).

NOTE:
The engine cover already has a relief to accommodate the drive belt tensioner. This relief needs to be trimmed to provide additional clearance.





4. Mark a guide line on the engine cover that is approximately 10mm (3/8") larger than the original opening.
See Figure 4.

NOTE:
Do not use hand tools or abrasive discs to cut the engine cover (hand tools will crack the engine cover and abrasive discs will melt the cover). Only high speed rotary burr tools should be used to modify the engine cover.





5. Using a rotary burr tool, modify the engine cover by increasing the opening over the drive belt tensioner to the previously made guide line. See Figure 5.

6. Reinstall the engine cover and tighten the three nuts. See Figure 1.
Tighten the engine cover nuts to 6 Nm (53 lb-in).

7. Return the vehicle to the customer.