Electronic Throttle Actuator: Service and Repair

Removal

CAUTION: This process assumes the use of the original throttle cable. The cable setting procedure in this instance is NOT appropriate for a new cable; please see Throttle Cable/Linkage if a new cable is to be installed.

1. Disconnect the battery ground lead.
2. Remove the air cleaner cover/intake assembly.





3. Disconnect 3 multiplugs & 1 vacuum pipe.





4. Rotate the throttle quadrant to allow disconnection of the inner cable





5. Release the throttle cable locking nut & displace the outer cable from the abutment bracket

NOTE: Do not disturb the adjusting nut





6. Remove coolant hoses (2)
- Mop up any spilt coolant & plug the hoses





7. Release the multiplug from the bracket under the LH side of the assembly





8. Remove the throttle body to induction elbow fixings (4) and pull the assembly clear
- Discard the gasket & clean all traces from the induction elbow mating face
- Blank off the inlet tract to prevent the ingress of foreign matter





9. Remove the throttle cable & intake duct brackets

Installation





1. Assemble the throttle cable & intake duct brackets & tighten the fixings to torque

2. Ensuring that the mating faces are clean & using a new gasket, fit the throttle assembly





- Tighten the fixings (4) to torque

3. All other aspects of the installation are a reversal of the removal procedure. However, particular attention must be paid to the following





4. Refit the throttle cable & ensure that there is neither tension nor slack in the cable
- Tighten the locknut without altering the setting or introducing twist into the cable outer

CAUTION: Under no circumstances may the quadrant be held clear of the throttle stop by cable tension

5. Check the kickdown setting to ensure that it is within specification & reset if required as detailed from step #6
6. Connect Scantool
- Read "Current Powertrain Data"





- Display PID 120F (pedal demand)





7. Push the throttle pedal until light contact is made with the kickdown switch

NOTE: Ensure that contact with the switch does not result in switch movement





8. The PID value should be 3.66 to 3.76 volts (2F9 ± A hex)
- If the value is outside these limits, proceed to step #9
- If the value is within these limits, proceed to step #13
9. Lift the carpet from around the kickdown switch
10. Disconnect the kickdown switch flying lead Connector (to avoid cable twist as the switch is rotated)





11. Adjust the kickdown switch to the value as defined in step # 8
12. Reconnect the kickdown flying lead connector & verify the setting.
13. Check the coolant level & correct as required