Throttle Control Actuator: Service and Repair

Removal
1. Remove the engine covers.
2. Remove the seven bolts retaining the upper half of the inlet manifold.
3. Undo the hose clip on the rubber spigot. Also disconnect the A/C valve's hose and remove the rear knock sensor's connector from the spigot. Remove the rubber spigot.
4. Unhook the two cables (accelerator and Cruise Control) from the butterfly lever and the bracket.
5. Remove the inlet manifold mounting strut by removing the upper screw and slacken the lower one.
6. Remove the cable conduit and disconnect the vacuum hose from the nipple on the bottom of the manifold on the left-hand side.
Lift up the upper half of the inlet manifold and rest it on one of the studs in the lower half of the inlet manifold or support it by means of a rubber mallet or the like.





7. Remove the four retaining nuts for the main throttle and TCS throttle. Withdraw the main throttle, remove the vacuum hoses and then move the main throttle to one side.
8. Unplug the TCS throttle body connector. Lift away the TCS throttle body with the two gaskets. Pay attention to the orientation of the pattern of holes in the outer gasket.
9. Remove the old gasket from the mating surfaces of the inlet manifold.





Installation
1. Clean the contact surfaces between the main throttle body, - the TCS throttle body - and the inlet manifold. Remove any gasket residue and clean the mating surfaces of the inlet manifold.
2. Install a new inner gasket on the inlet manifold, install the TCS throttle body in position, and plug in the connector.
3. Install a new outer gasket on the TCS throttle body. Make sure that the pattern of holes is correctly oriented.
4. Install the main throttle body in position and tighten the four (4) retaining nuts.
- Tighten to: 8 Nm (6 ft lb)
5. Connect the vacuum hoses to the main throttle body.
6. Install a new gasket on the mating surface of the inlet manifold and correctly position the upper half of the inlet manifold.
7. Tighten all the inlet manifold retaining bolts. Start with the bolts in the centre and continue alternately outwards.
- Tighten to: 20 Nm (15 ft lb)





8. Tighten the mounting strut on the rear of the inlet manifold.
- Tighten to: 20 Nm (15 ft lb)
9. Connect the vacuum hose to the nipple under the inlet manifold on the left-hand side and tighten the clip.
Secure the cable conduit.
10. Hook the cables onto the butterfly lever.
11. Install the rubber spigot and tighten the hose clip. Connect the A/C hose and fasten the rear knock sensor's connector to the spigot.
12. Install the covers over the engine.
13. Drive the car on the road and check the operation of the TCS.