Accelerator Cable Replacement - 2.0L Engine
1. Open hood.
2. Remove air intake resonators. See Figure 1.
3. Remove coolant recovery reservoir bolts, then position reservoir aside.
4. Remove traction control motor cover. Refer to Figures 1 and 2.
5. Disconnect traction control motor electrical connector. Refer to Figure 2.
6. Disconnect accelerator cable from traction control motor. See Figure 2.
7. From inside vehicle, disconnect accelerator cable from accelerator pedal.
8. Push accelerator cable and cable bulkhead grommet into engine compartment.
9. Remove accelerator cable from vehicle.
10. Drill two (2) holes in EGR backpressure transducer (DPFE) bracket as follows:
^ Place mark for first hole at 3/8 inch down from top of bracket and 1 inch in from passenger side of bracket. Refer to Figure 3.
^ Place mark for second hole at 3/8 inch down from top of bracket and 7 inches in from passenger side of bracket. See Figure 3.
^ Using punch, indent marks in plate to aid in drilling.
^ Cover throttle body with shop towel to prevent metal shavings from entering.
^ Using a 7/32-inch drill bit, drill out both holes in bracket. See Figure 4.
11. On new accelerator cable, measures 15-5/16 inches down from bulkhead fitting and mark cable with a piece of tape. See Figure 5. Make sure the green and yellow bands are flush to the bulkhead fitting before measuring.
12. Position new accelerator cable in the vehicle.
13. Connect accelerator cable to traction control motor.
14. Loosely route accelerator cable along DPFE bracket and through bulkhead.
15. From inside vehicle, connect accelerator cable to accelerator pedal. Make sure cable bulkhead grommet is fully seated.
16. Install two (2) supplied pushpin fasteners into the holes drilled previously. Refer to Figure 6.
17. Using tie strap portion of fasteners, secure accelerator cable to DPFE bracket. See Figure 6. Place taped location of accelerator cable under tie strap closest to the ignition control module.
18. Install coolant recovery reservoir. Tighten screws securely.
19. Adjust accelerator cables as follows:
^ Make sure clips from both accelerator cable adjusters are removed. See Figure 7.
^ Pull Accelerator cable housing away from both adjusters to slacken cables. See Figure 8.
^ Remove accelerator cable from throttle body lever and cable bracket.
^ Place a 1.3 mm (0.05 inch) wire through traction control motor pulley alignment holes. See Figure 9. The wire should not contact motor housing.
^ Using prop tool, fully depress and hold accelerator pedal (this will set the first adjuster).
^ Install clip into adjuster on the accelerator pedal to traction control motor cable. See Figure 10.
^ Remove prop tool from accelerator pedal.
^ Connect accelerator cable to throttle body lever and cable bracket.
^ Fully depress and hold the accelerator pedal again (this will set the second adjuster).
^ Fine tune second adjuster: Pull accelerator cable housing out of adjuster until wide open throttle (WOT) at throttle body is achieved then install clip to lock the adjuster. See Figure 11. Observe position of throttle body air valve to ensure WOT is achieved.
^ Remove 1.3 mm (0.05 inch) wire from traction control motor pulleys.
^ Make sure the throttle body air valve moves to WOT position when the accelerator pedal is fully depressed. (If throttle body does not move to WOT position, the adjuster may be moved one notch to achieve WOT.)
^ With the accelerator in idle position, check the position of throttle body air valve. Air valve should be closed and accelerator cable should deflect 1-3 mm (0.04-0.12 inch) midway between accelerator cable bracket and throttle body fever.
20. Install traction control motor electrical connector and cover.
21. Install air intake resonators. Tighten bolt/nut to 3-5 Nm (27-44 lb/in).