Campaign - AIR Pump/Relay & Cruise Linkage
Work InstructionsGroup: 14, 30
Date: April 1994
Number: 310
SUBJECT:
MODEL 202.022
94-0411 REPLACEMENT OF SECONDARY AIR INJECTION (AIR) RELAY MODULE (K17) AND PUMP (M33)
94-0421 INSTALLATION OF MAINTENANCE-FREE CRUISE CONTROL LINKAGE
In vehicles within the Effective Serial Number Range below, the secondary air injection (AIR) pump (M33) must be replaced and the secondary air injection (AIR) relay module (K17) must be replaced if the production date stamped on the relay module is prior to 21.10.93.
As of December 1993, a new cruise control linkage assembly is installed which no longer requires a Special Tool and periodic maintenance (lubrication). Therefore, the life-time lube assembly must be installed in vehicles within the Effective Serial Number Range listed under subject 94-0421.
These procedures must be performed during the vehicles next scheduled maintenance or repair.
94-0411 REPLACEMENT OF SECONDARY AIR INJECTION (AIR) RELAY MODULE (K17) AND PUMP (M33)
Replacement of module (K17)
Procedure
1. Remove previous version secondary air injection relay module (K17, Figure 1) from fuse box and replace with new version (stamped with production date 21.10.93 or later).
2. Mark the new version relay module with a white paint dot for identification purposes.
Replacement of pump (M33)
Procedure
1. Disconnect battery ground cable.
2. Remove (plastic) front engine cover.
3. Unplug secondary air injection pump electrical connector and unbolt air pump ground wire.
4. Loosen poly-V-belt and slide off generator pulley.
5. Remove generator bolt securing secondary air injection pump harness clamp.
6. Lift vehicle.
7. Remove lower encapsulation panel.
8. Remove secondary air injection pump hose at pump.
9. Replace secondary air injection pump (M33, Figure 2) with modified version.
10. Mark the new version pump with a white paint dot for identification purposes.
11. Connect electrical connector to harness and reinstall bolt previously mentioned in step 3 (which bolted the ground wire to the front of the cylinder head).
Note:
The ground wire for the new version air pump is located inside the pump's electrical connector and is no longer separately bolted to front of the cylinder head.
12. Further installation is in reverse order of removal.
13. Erase engine codes using Hand-Held Tester (HHT).
14. Activate secondary air injection pump with HHT and check readings according to HHT display.
Parts Information
Part Name Part Number
Secondary air injection relay module 001 542 74 19
Secondary air injection pump 000 140 33 85
Warranty Claim Submission Information
Operation:
Check production date of secondary air injection relay module (Repair Code 10).
Replace secondary air injection pump (Repair Code 11).
Replace secondary air injection pump and relay module (Repair Code 12).
Note:
Operation with repair code 12 includes checking the production date of the relay module.
94-0421 INSTALLATION OF MAINTENANCE-FREE CRUISE CONTROL LINKAGE
Procedure
1. Remove vertical throttle return spring (1, Figure 1) and discard. The spring (1) is damaged during removal.
2. Disengage connecting rod ball socket at angle lever (2).
3. Remove horizontal throttle return spring (3) and discard. The spring (3) is damaged during removal.
4. Press off upper "E-clip" (4) retaining plastic drag lever and accelerator control lever. Press off lower "E-clip" (5) retaining fulcrum lever. Do not remove "E-clip" (7) retaining roller pin on fulcrum lever.
5. Slide plastic drag lever and metal accelerator control lever off shafts and move aside.
6. Disengage lower (connecting rod [6]) ball socket at fulcrum lever.
7. Slide off fulcrum lever assembly and discard. Before discarding old assembly. compare control rod length to that of the replacement assembly. Adjust new control rod to match old. Final adjustment is made in step 14.
8. Slide replacement fulcrum lever assembly onto shaft and secure with new "E-clip" provided (5).
Note:
The assembly's ball socket linkage has been permanently lubricated, i.e. it no longer requires periodic lubrication with a Special Tool.
9. Attach lower (connecting rod [6]) ball socket.
10. Slide metal accelerator control lever onto shaft, making sure roller pin of fulcrum lever rests in slot.
11. Slide plastic drag lever onto shaft and secure both drag lever and accelerator control lever with new "E-clip" provided (4).
12. Install new horizontal and vertical throttle return springs (1, 3).
13. Connect connecting rod ball socket to angle lever (2) and reinstall vertical throttle return spring (1).
14. Adjust accelerator control lever with connecting rod according to Service Microfiche. Engine 111. Combustion, Job. No. 30-1010.
Parts Information
Part Name Part Number
Cruise control linkage assembly kit* 111 070 31 21 26
*Includes: Assembly, part no. 111 070 31 21
Throttle return spring (1), part no. 111 993 14 10
Throttle return spring (3), part no. 111 993 16 10
E-clips (4, 5), part no. 006799 005009
Warranty Claim Submission Information
Operation: Cruise control linkage assembly, replace (Repair Code 11)