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Throttle position sensor 1.4Tdi - gaining access

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Anyone know how to get to the throttle pot on the TDi? Seems to me that the dash may have to come out, but if there's an easier way I'd like to know before commit.

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you don't have to take the dash out at all, just get some small tools and take an undertray out.

torch may help.

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I was under there last night fighting the clutch pedal, which is why I fancy making the hole really big by removing the dash. I'm 6'5", it's not fun working in such a small space.

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Is it the same as the SDI? 

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same set up on them all but the derv one is different.

tdi/gti easier due to hydro clutch 

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most things are harder....

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Take the seat out? It's never a fun position upside down with your arms pinned.

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then you get to lie on the seat bracket.

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I'm a bit closer to solving this. Managed to get the lower wiring connector block thing disconnected and out of the way. I can see the nut on the pot through the fuse box hole but still can't get my big hands to it. I think I can get a ratchet spanner to the nut but how to lock everything whilst I tighten it?

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Just spent some time on Elsawin and realised that you rotate the pot by loosening 2 screws from the clutch pedal side and then rotate the whole pot. For info, it's an m6 screw with a torx head. Don't know the size yet.

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5mm.

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Finally got there. Having tried to remove the pedal box and failed due to the number of other things that get in the way, I removed the fusebox, loom connector panel and relay board, plus the lower dash panels. Then I used a 90.deg. drill adapter on a battery drill to chop out the side of the plastic box surrounding the electrics, by poking the drill through the fusebox hole. There is already a rectangular cutout that I continued to the top of the box. I could now put my hand on the quadrant and loose nut. When I'd got it rotated to the best position, I pushed up on the quadrant using a long screwdriver alongside the throttle pedal and tightened the nut. I also replaced the nut with a locking item. You need to get rid of the washer to have enough thread to bite into the locking part of the nut. An alternative is to replace the plain washer with a nordlock. Getting to this position took a month, putting it all back together took under 20 mins. Starting from scratch, it should be under a couple of hours. The connectors are all colour coded and the relays only go one way.

 

What I have realised is that there is no endstop on my throttle pedal so it runs out of travel before it's hit the carpet. I think this is why the quadrant came loose. The part no. for the missing bit is 6N2 723 527.

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On 8/23/2018 at 6:35 PM, Sausage said:

Yeha, you done live data on the pedal in vcds yet?

Done it now. 0-100%. Result.

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