Throttle Cleaning Procedure

1. Ensure ignition is OFF and remains OFF throughout the procedure.

2. Open hood and place protective covers on the fenders.

3. Clean part-load breather. (Refer to Technical Bulletin 600-03, Service Action S474).

Note:
It is important to clean the part-load breather to ensure that the throttle body and bore do not become coated in the sticky carbon deposit again.

4. Disconnect vehicle battery.

5. Remove air intake tube/MAFS/cleaner cover assembly.





6. Disconnect throttle body electrical connectors and vacuum pipe. (Illustration 1)

7. Turn throttle pulley to fully open position.





8. Disconnect throttle inner cable from throttle pulley. (Illustration 2)

9. Undo and displace throttle cable adjusting nut.





10. Remove outer throttle cable from adjustment bracket. (Illustration 3)





11. Remove coolant hoses. (Illustration 4)

12. Insert suitable plugs into coolant hoses.





13. Reposition electrical connector from securing bracket under left side of throttle body. (Illustration 5)





14. Remove throttle body securing bolts. (Illustration 6)





15. Remove throttle body from induction elbow and discard gasket. (Illustration 7)

Warning:
Wear suitable gloves, clothing, face and respiratory protection during the following operations.

16. Open throttle butterfly.

Note:
The throttle blade should be held open during the cleaning process by actuating the throttle. Workshop tools should not be placed inside the throttle bore in order to keep the throttle blade open.





17. Using suitable cleaning agent, (see table shown) liberally spray both sides of throttle bore and butterfly.

18. Carefully close throttle butterfly.

19. Allow cleaning agent to soak for 10 minutes.

20. Open throttle butterfly.

21. Using suitable cleaning agent, (see table) liberally spray both sides of throttle bore and butterfly.

22. Using a soft clean cloth, clean residue from throttle body bore and butterfly.

Caution:
There is a grey colored Molybdenum Coating on the throttle bore adjacent to the butterfly. Take care not to remove this coating during the cleaning process.

23. Carefully close throttle butterfly.

24. Manually work the throttle blade to ensure that it operates smoothly by gently pressing the throttle blade down to the closed position. Release the throttle butterfly. It should open at the same rate as it is released. If the throttle butterfly remains closed for a fraction of a second or longer after removing finger pressure, repeat the cleaning process.

25. Conduct another manual pressure test again after repeating the cleaning process, and if no sticking is evident continue to the next step.

Note:
If the butterfly is still sticking partially or fully closed, please contact the Technical Hotline for further information.





26. Install new gasket to throttle induction elbow, install throttle body and tighten securing bolts. (Illustration 8)





27. Reposition and install electrical connector to retaining bracket left side under throttle body. (Illustration 9)

28. Remove and discard blanking plugs from coolant hoses.





29. Install coolant hoses. (Illustration 10)





30. Install throttle body electrical connectors and vacuum pipe. (Illustration 11)





31. Reposition and install throttle outer cable to adjustment bracket. (Illustration 12)

32. Install but do not fully tighten outer cable adjustment nut.

33. Turn throttle pulley fully open.





34. Reconnect throttle inner cable to throttle pulley. (Illustration 13)





35. Adjust throttle cable. (Illustration 14)

36. Tighten throttle cable adjusting nut.

37. Install air intake tube/meter/cleaner cover assembly.

38. Check coolant level and top up if required.

39. Reconnect vehicle battery. (See Workshop Manual, JTIS CD ROM 1997-99 XK or XJ, section: 414-01, SRO 86.15.15)

40. Remove fender protector covers and close hood.