Usage:
Parts Preparation and Shaft / Throttle Housing Bearing Installation
1. If visibly dirty, wash the throttle housing (1) ( before installing the needle bearing), butterfly plate (7), end cap (4) and coupler (14). Do not use ultrasonics. Use an air gun to blow out the carrier assembly.
2. Press needle bearing (2), seal end first, into throttle housing (1) with a socket. The socket to be used is a 12 millimeter socket on a 1/4 inch drive. The socket that is used must have an outside diameter between .650 - .680 inches.
Figure 3-1. Installation of Shaft / Throttle Housing Bearing
Install the Shaft and Butterfly Plate
1. With throttle housing (1) setting as shown, hold butterfly plate (7) inside the throttle throat with the word "top" in the position shown.
2. Insert the bearing race end of shaft (9) into throttle housing (1) from left to right, through butterfly plate (7) and into needle bearing previously installed in the throttle housing.
NOTE: The plate must be able to rotate as shown in the lower photo of Figure 3-2.
To ensure proper installation, note the position of the coupler screw access port (1a) in relation to the word "TOP" on the butterfly plate. Do not secure the butterfly plate at this time.
Figure 3-2. Install the Shaft and Butterfly Plate
Install the Carrier Assembly
1. Apply a light film of petroleum jelly to O-ring (15a) and Glyd seal (15b). Place carrier (15) over shaft (9) and gently push it down into place. Some resistance will come from Glyd seal (15b) slipping onto the shaft race and some from O-ring (15a) slipping into the housing counterbore.
2. Make sure carrier assembly (15) is completely seated, then apply one drop Loctite 243 to screws (16) and secure the carrier to throttle housing (1). Torque the screws to 7.0 ± 0.4 lb-in (0.79 ± 0.05 N·m).
Figure 3-3. Install the Carrier Assembly
Secure the Butterfly Plate and Install the End Cap
1. Secure three screws (6) through butterfly plate (7) and start them into the shaft.
2. To ensure butterfly plate (7) is properly located on the shaft (9) and in the throttle throat, use your fingers to firmly close the side with the word "TOP" down several times to center it in the bore. A slight bind will be felt in the closed position. Hold it there while you tighten the center screw (6). Continue holding it in place and torque the three screws (6) to 72 ± 4 lb-in (8.1 ± 0.05 N·m).
3. Apply petroleum jelly to O-ring (3) and install it in the groove in throttle housing (1).
4. Apply Loctite 242 to two screws (5). Secure end cap (4) to throttle housing (1). Torque the screws (5) to 13.0 ± 0.7 lb-in (1.47 ± 0.08 N·m).
Figure 3-4. Secure the Butterfly Plate and Install the End Cap
Install the Coupler
1. Slide the wide section of coupler (14) on actuator shaft (13a) with the screws (14a) & (14b) at the bottom as shown. Leave approximately a 0.070 inch (1.78 mm) gap between the coupler (14) and the actuator housing.
2. Tighten screw (14a) on the actuator side of coupler (14). Torque to 78 ± 4 lb-in (8.8 ± 0.05 N·m). Leave screw (14b) loose.
3. Install O-ring (17) on actuator (13). Apply a light film of petroleum jelly to the O-ring.
Figure 3-5. Install the Coupler
Attach the Actuator to the Throttle Housing
- a. With return spring: With butterfly plate (7) fully closed (CCW) and with actuator (13) tilted slightly CCW, slide the coupler completely onto the throttle shaft until the actuator housing is against throttle housing flange (1a).
- b. Without return spring: Turn butterfly plate (7) approximately 45° from the closed position. With actuator (13) tilted slightly CCW, slide the coupler completely onto the throttle shaft until the actuator housing is against throttle housing flange (1a).
1. Determine if the actuator has a return spring by rotating the shaft. After determination, do the following:
2. Insert four screws (12) with flat washers (18) through the actuator housing and the slotted holes in housing flange (1a) Secure but do not tighten with four flat washers (10) and four nylok nuts (11).
Figure 3-6. Attach the Actuator to Throttle Housing
Set the Throttle Gap
1. Rotate actuator (13) CW until there is a 0.012 inch (0.30 mm) gap between butterfly plate (7) and the throttle throat. If the flange slots do not allow enough rotation to establish the 0.012 inch (0.30 mm) gap, pull the coupler off the throttle shaft, rotate the actuator one serration CCW, and try again.
2. Also check to see that the valve can actuate from fully closed to fully open. If not, rotate the actuator one serration and try again.
3. After achieving the 0.012 inch (0.30 mm) gap, tighten four nuts (11). Recheck the gap. Using a cross-hatch pattern, torque the nuts to 12.0 ± 0.6 lb-ft (16.3 ± 0.8 N·m). Go back and recheck the torque a second time.
Figure 3-7. Set the Throttle Gap
Tighten the Coupler and Install Access Port Plug and Nameplate
1. Insert an Allen wrench (A) through the coupling screw access port (1a) and tighten the coupler screw on the throttle shaft side. Torque to 78 ± 4 lb-in (). Re-check the gap at 0.012 inch (0.30 mm) and the butterfly plate for smooth rotation.
2. Install O-ring (19) on plug (8). Apply petroleum jelly and install it in access port (1a). Turn it in tight.
Figure 3-8. Tighten the Coupler and Install Access Port Plug