Throttle Cable/Linkage: Service and Repair

Accelerator Cable:

CABLE REMOVAL

1. Disconnect the accelerator cable from throttle cam.
2. Loosen locknuts on cable bracket and disconnect cable and rubber grommet from bracket.
3. Disconnect accelerator cable from pedal lever by disconnecting cable retaining clip from lever.
4. Feed cable through bulkhead into engine compartment.
5. Remove accelerator cable by pulling it out of the routing hole in the bulkhead.

INSTALLATION

1. Feed the accelerator cable through the routing hole in bulkhead.
2. Connect the accelerator cable retaining clip to the pedal lever.
3. Connect the accelerator cable and rubber grommet to the cable bracket.

NOTE: On 1.8L vehicles, accelerator cable connects to lower half of throttle cam. On 1.9L vehicles, accelerator cable connects to upper half of throttle cam.

4. Connect the accelerator to the throttle cam.
5. Tighten the locknuts on the cable bracket.
6. Adjust the accelerator cable deflection.

Accelerator Cable:

THROTTLE CLOSED POSITION ADJUSTMENT

1. Measure the accelerator cable deflection at the midway point between the throttle cable bracket and the throttle cam. The deflection should be 1-3 mm (0.04-0.12 inch).
2. If necessary, loosen the locknuts on the cable bracket and adjust the cable deflection until within specification.
3. After the proper adjustment is achieved, tighten the cable bracket locknuts.

WIDE OPEN THROTTLE ADJUSTMENT

1. Have an assistant press the accelerator pedal to the floor board.
2. Verify that the throttle plate is in the wide open position while the throttle pedal is pressed to the floor board.
3. If the throttle plate is not in the wide open position, have the assistant keep the accelerator pressed to the floor board while you adjust the locknuts on the cable bracket. Adjust the nut until the throttle plate is in the wide-open position.
4. Have the assistant release the accelerator pedal. Verify throttle plate is completely in the closed position.

ACCELERATOR PEDAL AND RETURN SPRING

Accelerator Cable:

1. Remove the accelerator cable from the pedal lever by disconnecting the cable retaining clip from the lever.
2. If equipped, disconnect the vehicle speed control cable from the pedal extension lever.
3. Remove the bracket mounting bolts and remove the accelerator pedal and lever, bracket, and return spring assembly.

Pedal Lever Return Spring:

Pivot Pin Retainer:

4. Using a screwdriver, disconnect the return spring tension hook from the pedal lever.
5. Using a screwdriver, remove the E-clip from the pivot pin.
6. Remove the pivot pin retainers that connect to the pivot pin and bracket.
7. Pull the pedal, lever, and the pivot pin assembly out of the bracket and return spring.
8. Remove the return spring.

INSTALLATION

1. Place the return spring into its mounting place.
2. Install the pedal, lever, and pivot pin assembly by piloting the pivot pin through the bracket and return spring.
3. Install the pivot pin retainers onto the pivot pin and bracket.
4. Install a new E-clip onto the pivot pin.
5. Position the return spring tension hook onto the pedal lever.
6. Position the pedal and return spring bracket and install the mounting bolts. Tighten the bolts to 8-11 Nm (69-95 lb. in.).
7. If equipped, connect the vehicle speed control cable to the bracket.
8. Connect the accelerator cable to the pedal lever by connecting the retaining clip to the pedal lever.

SPEED CONTROL PEDAL EXTENSION LEVER

REMOVAL

1. Remove the accelerator pedal and return spring.
2. Using a screwdriver, remove the E-clip from the pedal extension lever pivot point pin.
3. Remove the outside retainer from the pivot pin on the pedal extension lever.
4. Remove the pedal extension lever and pivot pin inside retainer.

INSTALLATION

1. Install the inside retainer on the pivot pin.
2. Install the pivot pin through its mounting holes in the bracket.
3. Install the outside retainer on the pivot pin.
4. Install the E-clip onto the pivot pin.
5. Install the accelerator pedal and return spring.