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As a complete Car mechanic Novice, I thought I'd share my first real experience of sorting something on my van!

This is an idiots guide to removing the throttle cable for lubrication or replacement on a 1.9TD as they often get extremely stiff. The difference even lubricating makes is amazing! So I would try this first before replacing. T:


1). Working from the end of the cable which fastens to the engine, unhook the Red section of the cable seen the picture below from its holder.



2). Pull the very end of the cable off where it fastens the the engine. This pulls upwards towards you.



3). Take the cable out of all its holders around the engine.



4). From inside the cab, get your head under - near the peddles. You will see that on the end of the gas peddle there is a hook that clips onto the end of the peddle. Undo this and then you will be able to pull the cable out in the engine bay.



Its in the top right of this picture



Finally just undo the electics that fasten to the cable and you should be able to pull the whole cable free.




5). Either lubricate with a fine lubricant (I used GT85 which I use on my bike cables when they're getting a little stiff), or replace the cable completly.



My first try at a "How to" photo guide aswell. If it helps someone to get their trottle cable
 

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Re: Idiots Guide to Throttle Cable Lubrication / Replacement! - 1.9TD

Hi Revelbikes

Great, was thinking about trying this the other weekend, but bottled it as wasnt sure which cable and how to release it....

I take it when you pull the cable free you pull it through from the inside (once its all disconnected under the bonnet) and then replace it in the reverse order!

I'm off down the local VW garage to get a new one and fit it at the weekend - Thanks
 

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Re: Idiots Guide to Throttle Cable Lubrication / Replacement! - 1.9TD

Bludy excellent guide dude!!

Just did mine. sprayed some lube down the wire and pulled it back and forth. The response is so light on the peddle now!!

Best bit it was all freeeeeeeee!!!
 

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Re: Idiots Guide to Throttle Cable Lubrication / Replacement! - 1.9TD

Hi Revelbikes

Great, was thinking about trying this the other weekend, but bottled it as wasnt sure which cable and how to release it....

I take it when you pull the cable free you pull it through from the inside (once its all disconnected under the bonnet) and then replace it in the reverse order!

I'm off down the local VW garage to get a new one and fit it at the weekend - Thanks
Hi mate,

Un hook the throttle from the engine end (inbetween the fan and engine) Then you're able to bring the whole cable out and it will only now be attached to the accellerator pedal. So now go inside the cab, slide the seat right back so you have enough room, and have a look at the end of the accellerator pedal. the cable literally hooks onto the end of it!

Unhook this and then go back outside to engine and you'll need to take the electric clip off which is near where the cable goes into the cab through the firewall. Then the thing should slip straight out. PM me if you don't quite understand what I mean!
 

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Re: Idiots Guide to Throttle Cable Lubrication / Replacement! - 1.9TD

Just wanted to thank you for this report just used your instructions to change mine as had tried lubricating but just wansnt right cant believe how much different the van drives its pulls away like my car does now :) was so worth the money buying a new cable :)
 

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Re: Idiots Guide to Throttle Cable Lubrication / Replacement! - 1.9TD

Hi mate,

Un hook the throttle from the engine end (inbetween the fan and engine) Then you're able to bring the whole cable out and it will only now be attached to the accellerator pedal. So now go inside the cab, slide the seat right back so you have enough room, and have a look at the end of the accellerator pedal. the cable literally hooks onto the end of it!

Unhook this and then go back outside to engine and you'll need to take the electric clip off which is near where the cable goes into the cab through the firewall. Then the thing should slip straight out. PM me if you don't quite understand what I mean!
Top man - Thanks for the advise, did this a few weeks ago and the van is like a different beast! The old cable was literally down to the last 3 or 4 strands, so Im glad I did it. There was a lot of broken cable snagging its movement.

No longer will I be playing dares when I pull out at a round about and there's no power!
 

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Re: Idiots Guide to Throttle Cable Lubrication / Replacement! - 1.9TD

Nice write up and pitures, well easy to follow.

Watch out when disconecting or connecting the cable to the throttle arm on the pump. As if you move the arm in a dirrection other than what its suppost to move you can cause a seal to move and end up like me with diesel leaking from the pump onto the alternator. (there are other posts stating this, ah if only I had a time machine).

Anyone got any suggestions what I should do, new seals (i'm handy but no mechanic) or is it better of going to see a diesel (bosch) specialist?
 

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Re: Idiots Guide to Throttle Cable Lubrication / Replacement! - 1.9TD

Great 'how to', just got my new cable and will be doing it tonight. My accelerator feels more like my clutch at the moment so hopefully this will make it feel more sprightly!!
Is it a real git to get it off the pump end? I'm off camping this weekend and don't want to screw up any seals on the pump.
The one on there has a metal hood on it but the replacement doesn't - do I have to put the hood on the replacement one?
Cheers
Paul.
 

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Just got my new cable as the accelerator feels more like a clutch at the moment.
I've notice that the orginal cable has a metal hood over the connection at the pump end.
Does this need to be replaced onto the new cable when changing them?
Is it a real pig to get the pump end off?
Cheers
 

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Really good guide mate.

Have exactly this problem at the moment and will defo follow your instruction.

What a relief too - though I had a serious power prob, so cheers bud!
 

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Re: Idiots Guide to Throttle Cable Lubrication / Replacement! - 1.9TD

Nice write up and pitures, well easy to follow.

Watch out when disconecting or connecting the cable to the throttle arm on the pump. As if you move the arm in a dirrection other than what its suppost to move you can cause a seal to move and end up like me with diesel leaking from the pump onto the alternator. (there are other posts stating this, ah if only I had a time machine).

Anyone got any suggestions what I should do, new seals (i'm handy but no mechanic) or is it better of going to see a diesel (bosch) specialist?

this has just happened to me , what a nightmare i only wanted to lube the cable ... as said "be careful"

what do i do now...???
 

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Re: Idiots Guide to Throttle Cable Lubrication / Replacement! - 1.9TD

I'm guessing it will be a similar story for a 2.5?
will have a crack at it tomorrow.
 

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I purchased a new cable, but there was no slot for the EGR wires, so I pulled out the old one gave it a good auld doss of WD40 down the cable ends, let it get into the nooks and crannies, put it back in, and shes working fine.... A:A:

Cheers for the guide T:
 

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Top man! Just done mine but left it fastened on the peddle just held it up after unclipping from accelerator and poured oil down spot on thanks
 

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Just wanted to say thanks for posting this. I have just followed this, step by step. First "mechanical" thing I've ever done and it worked a treat! Thank you!!
 
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