Date sent: 15 May 1996 13:55:13 PDT From: "Evans, John@IESD/TOG"
Subject: FW: BCDD To: a-powell1@TAMU.EDU In keeping with El Presidente's (Carl) charge to post a repair process...... I wrote this procedure for the Boost Control Deceleration Device (BCDD) on the L28e's. The photos are being developed and I'll send in a few days. Editorial license is cool with me. John firstname.lastname@example.org IZCC 410 BCDD repair procedure - or how to fix the bloomin' thing. Tools needed: 6mm allen wrench 6mm socket 10 mm socket #2 phillips screw driver flat blade screwdriver gasket remover or a razor blade needle nose pliers regular pliers gasket material hemostat carb/FI cleaner a small container to put parts in A six pack of Beck's beer Since I really did not want to try to remove just the BCDD from the bottom of the throttle body, I elected to take off the whole unit (throttle body & BCDD) together. 1. Remove the two screws hold the metal tubing connector at the top of the throttle body that are attached to the Cold Start valve hose. No need to remove the Cold Start valve itself. 2. Remove the emissions hose located immediately above the idle set screw 3. Remove the lead from the throttle valve position switch. There's a small retaining wire clip at the base. Remove this and pull the electrical lead off the switch. 4. Using the needle-nose pliers, position them against the throttle linkage connector and gently pry and remove the plastic (yellowish ball looking) connector. 5. Disconnect the black wire that is running from the BCDD solenoid. HAVE A BEER 6. Loosen three metal clamps for the rubber air intake boots fore and aft of the Air Flow Meter (AFM). 7. Remove the rubber boot between the AFM and throttle body 8. Remove the AFM. Caution: Careful here. At the underside of this thing is a fairly sensitive and substantial electrical connection. Remove this connection (similar to the throttle valve switch) and place the AFM well outta harms way. 9. Using the allen wrench remove the throttle body from the intake manifold. This is where I had to be creative and careful. My allen wrench was forged with a 90 degree turn in the thing. I used my Dremel with a cut off wheel and cut off the angle and then used a 6 mm socket and unscrewed the allen screws. DO NOT remove the screws until you eye ball the configuration of the throttle linkage ball connector, the return spring for the throttle valve AND the return spring hold down. 10. When you get the screws almost all the way out remove them in the following order. If you consider yourself directly in front of the throttle body, remove the screw at 10 o'clock, then remove the one at the 8 o'clock position, 4 o'clock position and lastly at the 2 o'clock position. 11. Pull off the throttle body AND the attached evil BCDD. 12. The base of the BCDD has 7 screws running the perimeter of the thing. Remove the screws one-at-a-time. THIS IS IMPORTANT. The three screws that need to be completely removed are the length of the BCDD assembly. If, in removing the screws you remove one that is short, just screw it back in and continue to the next screw. Remember, the three screws you need to remove run the length of the throttle body. 13. With the three screws removed, rap the side of the BCDD with a screw driver to get it off of the throttle body. 14. Remove the gasket. 15. Make a new gasket that blocks ALL holes except for the .45 cal bullet looking diaphram and the three holes for the screws to secure the BCDD to the throttle body. 16. I took this opportunity to clean the interior and exterior of the throttle body with the carb cleaner and a tooth brush. However, since the throttle valve switch is still attached take caution not to get any fluid inside this unit. 17. Reattach the BCDD to the throttle body and then reinstall the assembled unit. Note: Check the position of the throttle linkage ball connector. Make sure it is at least at an up angle of at least 45 degrees before reinstalling the throttle body. 18. Since the throttle return spring is kinda dangling, I reinstalled the allen screws in this order. 8 o'clock, 10 o'clock, 4 o'clock and finally 2 o'clock. 19. Reinstall the AFM and then hook everything else up. 20. My final step was to make the BCDD wire look as though it was connected. I just used electricians tape to block off the ends and then wrapped the wires together as if they were connected. _______________________________________________________________________________