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Old 12-19-2010, 12:19 PM
cdavidson cdavidson is offline
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Join Date: Mar 2008
Posts: 15
The final outcome.

I thought I'd post the final conclusion of this specific repair project. As you'll recall from above, the main problems were a sticky throttle and lack of power when cold.

I disassembled the throttle linkage. After breaking the first plastic socket on one of the push rods, I learned you pop those off their ball by prying the tip or sides of the socket with a flat blade screw driver. If you pry the rear side (that connects to the rod) you run a serious risk of splitting the socket where it connects to the rod. I ordered a new push rod, but JB weld worked fine on the original one. I noticed virtually all of the plastic linkage sockets were cracked (thanks again green party).

There are several pivot points and a couple of springs in the linkage. I cleaned all the ball and socket connection and used brake cleaner on the bell cranks and springs to remove a considerable amount of greasy goo. I also cleaned the throttle cable and the cable that runs to the transmission. I also re-install the rubber boot on the transmission cable. The transmission cable was a significant portion of the resistance until cleaned. I then used a dry lubricant on everything and reassembled. This fixed the sticky throttle.

While researching this problem, I ran across several references to the ALDA unit and specifically the pressure line to it. This line comes off the manifold and effectively informs the ALDA unit of the current boost pressure so it can adjust the fuel output. Because the line comes off the manifold it is subject to the goo introduced by the EGR valve. I disconnected the hose at the manifold. The port and hose looked clean, as did the end at the ALDA unit. Just to be sure, I shot the line with brake cleaner. At first the cleaner sprayed back out the end I was spraying it into. Then a big wad of black goo shot out of the other end of the hose. Then I noticed the in-line restriction port in the line. I love it when you get results.

I reassembled everything and took it for a spin in the now 9 degree weather. It ran like a champ. No sticky throttle and the power was normal. I'd say the moral of the story is check to simple stuff first!

Thanks everyone for the suggestions and help.
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