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Throttle Return Spring Installation Guide

The document provides instructions for replacing a throttle return spring on a 1995 Jaguar XJ-6 Vanden Plas as outlined in technical service bulletin 05-1-26am5. It describes disconnecting the accelerator cable and cruise control linkage, removing the throttle assembly cap, and taking out the old spring. The replacement spring must be tensioned by rotating its extension one full turn counterclockwise before reinstalling. Test driving with the new spring installed found the throttle was still sticking, so a modification was proposed - unwinding the old spring half a turn and reinstalling with an extra full turn of tension - which solved the sticking issue upon a second test drive.

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152 views13 pages

Throttle Return Spring Installation Guide

The document provides instructions for replacing a throttle return spring on a 1995 Jaguar XJ-6 Vanden Plas as outlined in technical service bulletin 05-1-26am5. It describes disconnecting the accelerator cable and cruise control linkage, removing the throttle assembly cap, and taking out the old spring. The replacement spring must be tensioned by rotating its extension one full turn counterclockwise before reinstalling. Test driving with the new spring installed found the throttle was still sticking, so a modification was proposed - unwinding the old spring half a turn and reinstalling with an extra full turn of tension - which solved the sticking issue upon a second test drive.

Uploaded by

bibibibibiib123123
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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1995 XJ-6 Vanden Plas

Work-around for Item 3 (Throttle-


Return Spring) of TSB 05-1-26am5
TSB Instructions
• ISSUE 3 - REPLACING THROTTLE
RETURN SPRING - NORMALLY
ASPIRATED
• 1. Disconnect the inner accelerator
cable from the throttle assembly.
• 2. Remove the cruise control linkage
pin and circlip.
• 3. After removing the three Torx head
screws that retain the throttle
assembly cap to the pedestal,
carefully remove the cap sub-
assembly. Note the position of the
straight extension of the throttle
return spring.
• 4. Unhook the throttle torsion spring
(Illustration 9) from the throttle shaft
actuator and then remove the spring
and the sleeve from the shaft.
TSB Continued
• 5. Remove the sleeve from the spring and
discard the spring.
• 6. Insert the sleeve into the replacement
spring. Install the sleeve and spring on
• the throttle shaft and hook the spring on to
the actuator.
– Note: The throttle return spring must be
tensioned, (pre-loaded) by rotating the
straight extension one full turn
counterclockwise until it can be installed in
the same position as the original spring.
• 7. Carefully reinstall the cap to the throttle
assembly noting the lever location, and
install and tighten the screws.
• 8. Reconnect the cruise control linkage.
• 9. Reconnect the accelerator cable to the
throttle assembly.
• 10. Check the operation of the throttle
assembly.
Tools
• ¼” drive Torx T-25
• ¼” drive 6” extension (wobble ext if you have it)
• ¼” drive ratchet
• Magnet
• Needle-nose pliers
• Wire pliers
• Vise
• Small spade screwdriver
Discovery Phase
As-Discovered upon dis-
assembly Proper Orientation
Test-Run 1
• I put it all back together with
the spring in the proper
orientation and took it out for
a test-drive.
• No joy, I found it was still
sticking high and brought it
home, popped the bonnet and
went in for a bite to eat while
things cooled a bit.
• Upon returning, I noticed I’d
left the EGR unplugged for the
test run. Since it ran EXACTLY
as it has previously, decided it
would not affect my results
and tore back into the spring-
works
Modification Plan
• Motorcarman: “You don't need a new spring. I just unwind the old spring a half turn with pliers and then go one EXTRA turn when
installing it again. You will find that it is too long so kinda guess how much too long, pull it back off, snip it shorter and then install it.”
Mark & Measure
Remove Insert and mark spring Release tension and keep track
for unwinding of your mark
Unwind ½ Turn
I clamped the free-end in the Incrementally straighten the last
vise coil with wire-pliers to mark
Re-Fit and Re-Mark
Test-fit after unwinding ½ turn Mark for cutting
Finish Forming
I clamped it back in vise to bend a slight hook in Decided to just leave the large end on rather
end, and broke the end off while forming it. than try to cut it off close to the hook
Installation
Don’t lose nor break this “insert”
or plastic collar! It keeps the spring seated
Test Run 2: Success!
Don’t forget the EGR Valve connector Ready for test!
when you are buttoning up. (No more sticky throttle)

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