Join Date: Aug 2004
Location: San Francisco, CA
throttle cable too short after new throttle body
the most annoying thing: just finished installing a new throttle body on my 2005 Elise (got it from Toyota) and it all went smoothly until the very end, after i attached the throttle cable to the throttle body, and found that the cable is now too short, even after taking up all the adjustment slack there is (by moving the two adjustment nuts away from the body all the way to the end of the threads) - the throttle is partly open (judging by the quarter pulley not reaching its rest stop nut, by about 5 mm) even when the throttle is fully closed.
i checked the throttle pedal and it looks like it is already as far up as it will go - so i can't get any more slack that way.
i have couple of ideas to try next, but they are a little wacky, so i am looking for better ideas:
1) i am thinking of grinding down the end of the adjustment threads on the cable so that i can move the adjustments nuts even further. the extra adjustment of almost one nut width might be enough.
2) there is some slack in the cable sheath where it goes around the pedals. so i could tighten that up, but that means unfastening all the cable sheath fasteners as it winds around the car, which seems quite involved and it's difficult to get the car up in the air where it happens to sit at the moment, and it's currently not drivable like this. and to help with that idea, i could use instructions anybody for replacing the cable - i have not been able to find any.
and the weird thing is: why is this even happening? - the throttle body i got looked to be the same as what was on the car, although i didn't take the time to compare the quarter-pulley in detail with the old (could still do that).
and why did i even get a new throttle body? - the old one wore out some space between the valve and the body which was causing high idle - it's a known problem described elsewhere (i had a hacked fix that worked for couple of years but doesn't anymore).
looking for better ideas to solve this. thanks!
Last edited by masheen; 03-30-2019 at 02:21 PM.