Remove, install and adjust the accelerator cable

• Press the throttle lever (diesel engine: injection pump lever) by hand until it reaches the full-throttle stop. The illustration shows the 1.6 L engine.

• Pull the nipple - 1 - of the accelerator cable out through the slot in the throttle segment.

• Pull the accelerator cable out through the bore in the abutment (bracket) and push out the rubber grommet - 2 -.

• Unclip the accelerator cable from the guides in the engine compartment.

  Note: for easier installation, it is advisable to mark the installed position and the attachment points on the accelerator cable with paint and transfer the marks to the new accelerator cable.

• Unhook the accelerator cable from the accelerator pedal and pull it through into the engine compartment. Push the grommet out of the bulkhead while doing so.

• Pull the accelerator cable through the bulkhead into the passenger compartment and hook it onto the accelerator pedal.

• Insert the rubber grommet into the bore in the bulkhead. Make sure it seals well.

• Route the accelerator cable in the engine compartment exactly as the previous cable and clip it into the brackets.

• Slide the rubber grommet onto the accelerator cable.

• Push the accelerator cable through the bore in the abutment, insert the rubber grommet into the bore and push on the cable sheath.

• Press the throttle lever (diesel engine: injection pump lever) by hand until it reaches the full-throttle stop.

• Insert the nipple of the accelerator cable through the slot in the throttle segment and slowly release the throttle lever. Lay the cable into the throttle segment while doing so.

• Fit the retaining clip - 3 - in the same position as on the previous accelerator cable, see illustration T-20129.

• Check the accelerator cable adjustment.

• Adjust the accelerator cable by moving the snap-in clip - 3 - on the abutment - 2 - so that the end - 1 - of the accelerator cable moves freely in the seat of the throttle lever, while the cable should have as little play as possible.

  The illustration shows the 1.6 L engine.

Adjusting the accelerator linkage is necessary after the injection unit, the intake manifold or parts of the linkage have been removed. Otherwise the throttle valve position is incorrect and leads to malfunctions of the Monomotronic system.

• Press the pull rod - 1 - off the head of the lever - 2 -. Make sure the deflection pulley - 3 - rests against the stop, see the following illustrations. The accelerator cable must be free of play; otherwise, adjust it as on the other engines.

1. 1

   Pull rod

2. 2

   Throttle lever

3. 3

   Idler pulley

4. 4

   Lever

5. 5

   Lock nut

6. 6

   Lock nut

7. 7

   Hex

• Start the engine and let it warm up until the coolant temperature gauge shows normal operating temperature.

  The interior blower and the radiator fan must not be switched on.

• Switch off the engine.

• Press the pull rod - 1 - onto the head - 2 -. A clearance of 0.7 mm to 0.9 mm must exist between the shoulders of lever - 2 - and - 4 -, see illustration T-20131. Warning: on new engines that have not been run in, the clearance is 1.6 to 1.8 mm.

• Otherwise, loosen lock nuts - 5 - and - 6 - and turn the pull rod - 1 - at the hex - 7 - until the correct value is reached. Retighten the lock nuts.

• Have an assistant press the accelerator pedal fully. At full throttle, the throttle lever on the injection unit must be fully open.