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RWD - K-Jet throttle body cleaning/removing steps

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K-Jet throttle body cleaning/removing steps 200 1980

Greeting All,

I'm in need of steps or process for removing and replacing
the throttle body in a 1980 240 2.1L. I'm wanting to clean
the throttle body. I've done this job on a non-k-jet a few times, but this
seems a bit more detailed and I didn't want to make any
mistakes along the way. It seems like removing the intake
manifold would be a good idea in order to get to the throttle
body.

All advice is appreciated.

Joseph in Snowy New Mexico





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K-Jet throttle body cleaning/removing steps 200 1980


It seems like removing the intake manifold would be a good idea in order to get to the throttle body


No. Don't do that. It isn't necessary.

I have not done this for a number of years but I have done it on both K-Jet and LH cars and removal of the intake manifold is definitely not required.

In either case, I didn't need a step-by-step. That doesn't mean I think I am smarter than you. That means I think you can reason it out.

But I will relate what I remember.

Obviously the so called bellows (a misnomer if ever there was one) needs to come off. This is the rubber bulb-looking item between the air meter and the throttle body. Loosen the two clamps. The rest is obvious. BTW, it is a little tricky to install but let's not get ahead of ourselves.

The throttle cable needs to be disconnected. I seem to recall one small cap screw needs to be loosened. Once again, when you are there looking right at it, you will know what needs to be done.

If there are hoses to the throttle body, make a sketch and label the hoses.

The throttle body needs to be removed. I don't recall that there's much more to it than that. You don't have the IAC to deal with.

However, one of the three nuts securing the throttle body to the intake manifold might seem a little tricky but it is not so much. For two of them the box end should slip right on. For the other you need to angle the wrench just a bit at first and them make it flush. Poor description, I know but, as before, when you get there you will see what I mean.

This is what I recall and you can do it.

Anyone reading this, please correct anything I may have got wrong.

But, Joseph, don't remove the intake manifold.


--
'80 DL 2 door, '89 DL Wagon, '15 XC70 T6





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K-Jet throttle body cleaning/removing steps 200 1980

Hi BulletProof ~
I'm glad I waited until tomorrow to do the job.
So after I remove the rubber ball then there are just three bolts holding up the throttle body attached to the intake manifold?
I was apprehensive because of so much stuff under the intake manifold.

Thank you...





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K-Jet throttle body cleaning/removing steps 200 1980


Three nuts. Intake manifold has studs. But, yeah, that's all that fastens the throttle body to the intake manifold.


--
'80 DL 2 door, '89 DL Wagon, '15 XC70 T6





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K-Jet throttle body cleaning/removing steps 200 1980

I cleaned the throttle body today.
What does that green wire attached to the throttle body spring mechanism do?
It is attached to the plate that strikes the idle screw.
If it becomes unattached what are the results?
At the end of the green wire is a small flat metal piece.

Mine was JB Welded onto the plate that strikes the idle screw.
It must have broken off during previous work.
It snapped off today and I reattached with KB Weld.

I have no idea what this wire does, I’m sure one of you know it’s purpose.

Thanks again for assistance.







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K-Jet throttle body cleaning/removing steps 200 1980


There is no wire like you describe in the normal configuration. Someone has added this later for reasons that are not clear.

If you follow the green mystery wire, where does it lead?


--
'80 DL 2 door, '89 DL Wagon, '15 XC70 T6





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K-Jet throttle body cleaning/removing steps 200 1980

I have to be honest--I did not look into this thoroughly now and it's been decades since I've dealt with this part but----I looked at my own 1980 245 and can see there is a green wire that goes to a vacuum valve mounted on the firewall just to the passenger side of the car. It causes the idle to rise when the A/C is on---been 15 years since my a/c worked :-( -- Things are too grungy in my throttle body area to make out exactly how it all works. Maybe it's related to the mystery wire. That also triggers this thought--isn't the + wire to the compressor green? -- Dave





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K-Jet throttle body cleaning/removing steps 200 1980


My '79 had that solenoid valve.

Yes, + wire to the compressor is green and the same wire continues to the aforementioned solenoid valve.

It seems unlikely that this would be the mystery wire unless someone re-routed it for some reason.


--
'80 DL 2 door, '89 DL Wagon, '15 XC70 T6





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K-Jet throttle body cleaning/removing steps 200 1980

Image and video hosting by TinyPic

Image and video hosting by TinyPic

Image and video hosting by TinyPic

I hope the pictures appear.

One shows the green wire's end plug.
Second one shows where the green wire goes into sleeve on passenger side of the firewall.
Third picture shows where it was originally JB Welded (I temporally have it holding on with a alligator clip). It came apart when I was attempting to unplug it (I did not know it was JB welded onto the throttle controller/part near the outer spring).





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K-Jet throttle body cleaning/removing steps 200 1980


Second one shows where the green wire goes into sleeve on passenger side of the firewall.

Does it actually go, "into the sleeve," as you put it or just run alongside it? Is it spliced to another wire? Can you follow it any further than point shown in your pic?


--
'80 DL 2 door, '89 DL Wagon, '15 XC70 T6





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K-Jet throttle body cleaning/removing steps 200 1980

I think you hit it on the head. At least you triggered some memories that had me reaching for an old notebook (March 2001). Trouble is, my notes were all about where the fuel lines went, and especially where all the lines connected for the vacuum amplifier operating the EGR in my '79, not the throttle body removal.

Good suggestion, not removing the intake manifold. If you do, you may not stop there and then you might wind up with some intense scope creep. It was, I believe, the impetus for the purchase of a digital camera that did close-ups, something that wasn't cheap in '01.

Or, who knows, you might decide to give the engine compartment the Michael Yount makeover. :-D


--
Art Benstein near Baltimore

Mother Superior called all the nuns together and said to them, 'I must tell you all something. We have a case of gonorrhea in the convent.' 'Thank God,' said an elderly nun at the back. 'I'm so tired of chardonay.





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K-Jet throttle body cleaning/removing steps 200 1980

Hi Art ~ thanks for helping again.
The accordian hose connects to the metal intake, does the metal intake just stay attached and the rubber ball comes off to allow access to remove the throttle body's three bolts?





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K-Jet throttle body cleaning/removing steps 200 1980

Yes, you have it. The air fuel unit stays where it is. What you hope, when you loosen the clamps on the big rubber ball/bellows/hose is it hasn't hardened in the Arizona climate. Should be able to squeeze it a little and pull it out from between the airflow meter and throttle body.

I had a look at ours. I think I would start by disconnecting the threaded rod linkage between the throttle body and throttle spool. Each end is a ball and socket joint like your shoulder. If you've done the LH version you remember there's a snap at the end you loosen before prying the socket off of the ball.

Then to get it out of the way, I'd unfasten the bracket holding the throttle spool. This is simple on mine, as there's no cruise, so I don't know if that would be your approach.

Then ours has EGR, so I'd have the intake side of that pipe to remove from the throttle body, along with the evap vac hoses on the back side, then the idle bypass on the front side has the AC vacuum switch, more hoses to get out of the way. This is where you could get into trouble maybe, as some of those idle air bypass hoses may be hard to find and easy to split, but to reach that inner nut on the throttle body and eventually pull it all loose, you've got to do that.

I have this short 13 combination wrench -- about 4" long. Its from one of Craftsman's higher end polished chrome offerings I guess, but it's box end is extra thin to fit the space around those TB nuts. Without it I think I'd be spending all my time on that inside nut.
--
Art Benstein near Baltimore

Generally speaking, you aren't learning much when your lips are moving.





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K-Jet throttle body cleaning/removing steps 200 1980

Hi Art,
What is the green wire attached to moving part that contacts the idle screw?

Thanks,
Joseph in New Mexico





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K-Jet throttle body cleaning/removing steps 200 1980

"What is the green wire attached to moving part that contacts the idle screw?"

I dunno. I'm inclined to agree with Don, it sounds like a hack. The wire to the microswitch for lambda controller's wide-open-throttle enrichment comes from the thermal switch and is green, according to a map I have for the new features in the '80. The adjustment notes say it should close the switch when the throttle is '5/32" to 1/32"' from the stop. Sounds to me from your description the switch is long gone.
--
Art Benstein near Baltimore

I totally take back all those times I didn't want to nap when I was younger.





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K-Jet throttle body cleaning/removing steps 200 1980


Art, what are you referring to as the thermal switch? I am thinking this is actually the frequency valve. I am looking at the 1980 B21F Lambda system wiring diagram.

But, no matter. Now when you say, "Sounds to me from your description the switch is long gone," do I understand you to mean that replacing the Lambda relay may be the solution?


--
'80 DL 2 door, '89 DL Wagon, '15 XC70 T6





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K-Jet throttle body cleaning/removing steps 200 1980

"...do I understand you to mean that replacing the Lambda relay may be the solution?"

Nothing like that. Ideally the missing switch would be replaced, if I read this right. I don't have a car with this; our '79 has no lambda and our 83 k-jet cars use the throttle actuated Microswitch for idle control.



--
Art Benstein near Baltimore

The letters T and G are very close to each other on a keyboard. This recently became all too apparent to me and consequently I will never be ending a work email with the phrase "Regards" again.





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K-Jet throttle body cleaning/removing steps 200 1980

Art- I'm totally at a loss at this point.
Can you send me an email so that I can send a
couple of pictures of this wire and its connection?

Jsegura525atAOL.COM

Thank you again

Joseph





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K-Jet throttle body cleaning/removing steps 200 1980


Okay. My 1980 model does not have that feature. I assumed Joseph's car does not.

Must have been a mid year change.

I always associate the micro switch with IAC, as you mentioned. But this is why the brickboard is a great resource. I've driven 240's since 1992 and yet I learn something new here at least once a month.


--
'80 DL 2 door, '89 DL Wagon, '15 XC70 T6





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