91, 740, VDO TPS


The TB pulley on our 91, 740 turns about at least 1/2" before I hear any click from the TPS switch. It was doing this before I adjusted it too. I have done the adjustments by the book.
But the books vary and I wonder if the editor or auto writer may have omitted something or missed a typo. All the aftermarket sources I read say to turn the TPS with no feeler gauges inserted between the screw and stop, until a click is heard and then stop at that position and tighten the TPS. They then tell you to adjust the link rod with a 1.0 mm feeler gauge inserted at the pulley idle position stop, and to proceed with the link rod adjustment (0.1 mm feeler should fit between the adj screw and stop position).

But the Volvo books and the ALLDATA CD ROM for the Regina cars ay differently. They say to insert a 0.25 mm feeler between the adj screw and the stop while adj the TPS, and then say to use a whopping 2.5 mm feeler at the pulley stop when doing the link rod. I don;t even know where to find a 2.5 feeler so I had to combine two 1 mm blades and a .5 mm blade for the job. Anyway after it was all done I still had the same 1/2" turn before any click, even though there were plenty of clicks while doing the procedure. I called Volvo and one of their techs told me to disregard the Volvo manual, further stating a few expletives.

Anyone else experience this. I think the Kickdown cable is way too loose but this is not related or a cause of this problem is it? What about a non taut to very loose Throttle cable?

diyer