Throttle body - removal and installation
Disconnect the negative battery terminal.
Remove the main throttle body as described in the previous section "Motronic M2.5 fuel injection system".
Disconnect the breather hose from the camshaft cover on the right side of the throttle body.
Disconnect the refrigerant hoses from the throttle body, marking their location for easier installation. There may be a coolant leak, so clamp the hoses to reduce coolant loss.
Remove the two bolts securing the throttle control motor to the throttle body.
Disconnect the two vacuum hoses from the front of the throttle body, noting their location for reinstallation.
Disconnect the throttle motor drive rod from the lever located on the side of the throttle body.
Remove the throttle body from the intake manifold. Remove the gasket.
Before installation, carefully wipe the mating surfaces of the RTU throttle body and the intake manifold.
Install the throttle body to the intake manifold with a new gasket.
Further installation is carried out in the reverse order of removal, taking into account the following.
Check if the cooling hoses are connected as they were before removal.
When connecting the drive rod (RTU) to the lever on the throttle body, check if the clip is engaged.
When connecting the vacuum hoses to the throttle body (RTU) check if they are installed correctly.
Install the main throttle body with a new gasket as previously noted.
After finishing work, check the refrigerant level and, if necessary, add it to the required level.
The throttle control motor of the RTU system - removal and installation
Disconnect the negative battery terminal.
Remove the air box from the top side of the throttle body as previously noted.
Disconnect the crankcase breather hose from the main throttle body.
Loosen the alternator bolts, then remove the top bolt, remove the drive belt from the alternator pulley and slide the alternator out of the way.
Remove the two screws and remove the throttle cable bracket from the intake manifold.
Disconnect the throttle control motor connector (which can be accessed from the generator side) from the throttle body.
Disconnect the throttle control rod of the RTU system from the throttle (pic. 4.113).
Loosen and remove the two bolts securing the throttle motor to the throttle body, then carefully remove the motor (pic. 4.115).
If at the same time the throttle control rod is disconnected from the electric motor, its location should be noted for subsequent installation.
Installation is carried out in the reverse order of removal, taking into account the following.
If required, check the correct location of the throttle control rod.
Before tightening the alternator bolts, tension the drive belt as directed in chapter 12.
Install the airbox as previously stated.
Electronic control unit - removal and installation
The electronic control unit for the RTU system is located inside the car next to the left front seat under a cover at the threshold.
Make sure the ignition is off, then disconnect the negative battery terminal.
Use a screwdriver to open the two locking nuts of the control box cover, then remove the nuts (pic. 4.114).
Carefully remove the control box cover, noticing how it is secured.
Take out the control box and holes, then remove the clamping screw of the plug connector. Release the clamps and remove the block.
Installation is in the reverse order of removal, but make sure that the cover snaps into the panel correctly.
Manual simplification switch
Removing
The switch for switching to manual control is located on the center console in the cabin.
Disconnect the negative battery terminal.
Carefully remove the tray from the center console. Disconnect the wire from the switch. Carefully push the switch through the top of the center console.
Installation
Installation is carried out in the reverse order of removal.
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