REMOVAL & INSTALLATION
See Figures 1, 2, 3 and 4
- Release the fuel system pressure as described previously in this section.
- Disconnect the air intake hose from the throttle body.
- Disconnect the accelerator and cruise control (if so equipped) from the throttle lever.
- Drain the engine coolant to a level just below the intake manifold.
- Remove the water hoses from the throttle body.
- Label, then disconnect all electrical wiring and vacuum hoses from the throttle body.
- Remove the four retaining bolts and separate the throttle body from the surge tank. Remove the throttle body gasket and cover the surge tank opening with masking tape to prevent anything from falling into the engine. Purchase a new gasket.
- Make sure all the gasket mating surfaces are clean.
- Position the throttle body and gasket onto the surge tank and install the four retaining bolts. Torque the bolts evenly in a diagonal pattern to 7-9 ft. lbs. To ensure uniform compression of the gasket, DO NOT overtighten the bolts or the gasket will be over-compressed and not seal properly.
- Connect the vacuum hoses, electrical wiring and water hoses to the throttle body. Make sure all connections are tight.
- Connect the accelerator and cruise control cables to the throttle lever and adjust them as described in this section.
- Connect the air intake hose to the throttle body and tighten the hose clamp.
- Fill the cooling system to the proper level with a 50% mix of antifreeze.
- Start the engine and adjust the idle speed.
See Figures 5 through 11Accelerator Cable
VEHICLES WITHOUT CRUISE CONTROL
On Excel and Sonata without cruise control, the throttle cable is adjusted by loosening the two screws on the slotted throttle cable bracket(s) attached to the surge tank. Move the bracket(s) as required until a slight tension in the cable is obtained. To check the cable tension, lightly press the cable with the tip of your finger. There should be 0-1mm of slack in the cable. Once the cable is properly tensioned, hold the bracket in place and tighten the two screws. Coat the cable and throttle lever with multipurpose grease.
On Sonata, if the throttle and cruise control cables were disconnected for any reason, there is a four part adjustment sequence to adjust cable tension. The four parts are as follows:
To perform the accelerator cable (pedal side) adjustment:
- Connect the accelerator cable to the pulley. Then, position the cable in the cable bracket and make the two locknuts A and B finger tight.
- Pull the cable tight so that the pulley rests against the stop and tighten locknut B until it is flush against the bracket. Then, back locknut B off one complete turn.
- Tighten locknut A. The cable should have approximately 1mm of slack.
To perform the accelerator cable (throttle valve side) adjustment:
- Connect the throttle valve side accelerator cable to intermediate pulley B. Then, adjust and tighten the cable locknuts so that there are just about equal lengths of the cable threaded portion on both sides of the cable housing bracket.
To perform the actuator cable adjustment:
- Connect the actuator cable to intermediate pulley C.
- Position the cable in the cable bracket and make the two locknuts A and B finger tight.
- Pull the cable tight so that the pulley rests against the stop and tighten locknut B until it is flush against the bracket, then back locknut B off one complete turn.
- Tighten locknut A. The cable should have approximately 1.5mm of slack with the pulley flush against the stop.
To perform the final cable adjustment:
- If not already completed, connect the accelerator cable to the throttle valve pulley and attach the cable and slotted bracket to the rear side of the surge tank. DO NOT tighten the two bracket mounting screws at this time.
Before proceeding with any further adjustments, make sure the throttle valve pulley is in the NORMAL idle position.
- Insert a 1.5mm shim or feeler gauge between intermediate pulley stops B and C and hold it there.
- Adjust the cable casing at the rear side of the surge tank until all slack is removed from the cable. If all slack is removed, the throttle stop bolt should be contacting the throttle valve lever. Make sure the throttle valve pulley does not deviate from the normal idle position during the adjustment.
- Once all slack is removed from the accelerator cable, tighten the two bracket mounting screws at this time.
- Remove the shim installed between the intermediate pulleys.