Removing and installing adjustment lever shaft with load impact damping — AUDI

Removing

Detach throttle mechanism coupling link on adjustment lever.
Unscrew the idling speed increase actuator bracket and disengage the angular lever.
Swing the securing clip -17- aside and press off the gas-filled strut -16-.
Using water pump pliers, hold the washer -2- on the outer edge and loosen bolt -1- by briefly applying moderate force.

Note:

This will ensure loosening of the bolt and not the threaded piece -9-.

Screw the bolt -1- out by a few turns and disengage the load damping spring -4- using a strong wire hook or a pair of pliers.

Remove the upper adjustment lever -7- with load impact damping spring, spring retainers -3- and -6- as well as guide bush -5-.
Remove the shim -8-.
Disengage the return spring -13-.

Notes:

Under no circumstances must the lower adjustment lever -11- turn on the adjustment lever shaft -15- before the relative installation position of adjustment lever to adjustment lever shaft has been marked.
After loosening the threaded piece, press the adjustment lever onto the adjustment lever shaft to prevent it from slipping on the splines.

Unscrew the threaded piece -9-.
Using a piece of wire, lift the washer -10- from the recess in the adjustment lever.
Mark the installation position of the lower adjustment lever -11- relative to the adjustment lever shaft -15- using a metal scriber.
Remove the lower adjustment lever with return spring -13- with spring retainers -12- and -14-.

Installing

Installation is carried out in the reverse order; note the following:

Note:

Order of washers and shims must always be maintained upon assembly.

Fit the return spring -13- with spring retainers -12- and -14-.
Set the lower adjustment lever -11- in place according to the marking applied.
Fit the washer -10- and tighten the threaded piece -9- to 10 Nm.
Engage the return spring with a wire hook -13-.
Before continuing with further assembly, check the idling speed and the cutoff speed => Page
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.

Notes:

If the idling and cutoff speed deviate only slightly from the specified value after assembly, the adjustment lever installation position is correct. Assembly may be continued.
If the engine runs much too fast (approx. 4000 rpm), the lower adjustment lever -11- was inserted incorrectly by one tooth in anti-clockwise direction on the adjustment lever shaft -15-.
If the engine runs much too slowly and the cutoff speed is not reached, the lower adjustment lever was inserted incorrectly by one tooth in clockwise direction on the adjustment lever shaft.

Fit shim -8-.
Fit the upper adjustment lever -7- with lower spring retainer -6-, guide bush -5-, load impact damping spring -4- and spring retainer -3-.

Note:

Ensure that the guide bush -5- engages in the shim -8-.

Screw in the bolt -1- with washer -2- by several turns.
Engage the load impact damping spring -4- and tighten the bolt to 10 Nm.
Press the gas-filled strut -16- on the ball stud and secure it using the securing clip -17-.
Check idling speed and cutoff speed and adjust as necessary => Page
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