Changing accelerator cable

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irollerdudek
480 Newbie
Posts: 11
Joined: Thu Mar 03, 2016 12:49 pm

Changing accelerator cable

Post by irollerdudek » Thu Mar 03, 2016 1:02 pm

I have one of the few 480ES in the US, so finding parts and help is not so easy. 1989 non turbo, manual. My accelerator cable assembly broke at the firewall plastic retainer and I can't figure how to remove it. It fits in a square hole and has what looks like a square retaining piece turned 45 degrees on the inside. Of course this is very difficult to reach, way above the pedals inside. Since the original cable is nla, I have sourced an aftermarket replacement cable after some searching, and hope it will fit. How can I remove the old cable assy without destroying it? Any help is very welcome. Thanks.

balto8
Knows an Aerodeck isn't a 480
Posts: 239
Joined: Tue Jul 22, 2014 3:02 pm

Re: Changing accelerator cable

Post by balto8 » Thu Mar 03, 2016 1:34 pm

Could you point where did you find the cable?
1991 480 Black Turbo
2012 Seat Exeo ST
2013 VW Polo TSI DSG

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jamescarruthers
480 Is my middle name
Posts: 2501
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: Changing accelerator cable

Post by jamescarruthers » Thu Mar 03, 2016 3:10 pm

Tell us more about your USA 480!

P.S. You need 10 posts to post pictures.
1987 Volvo 480 ES, 507274, 217 - Red (Ness)
2006 Citroen C6 Exclusive 3.0 petrol/LPG
2008 Mini Cooper convertible (Mau)

Previous 480's:
J123 CFU -- ES
J449 MNL -- ES auto
D864 CPV -- ES
L691 JFC -- Turbo
F70 MNR -- ES
H858 FGV -- Turbo auto
E981 KHM -- ES (509849)

irollerdudek
480 Newbie
Posts: 11
Joined: Thu Mar 03, 2016 12:49 pm

Re: Changing accelerator cable

Post by irollerdudek » Thu Mar 03, 2016 4:28 pm

I got the cable from Skandix in Germany. Their part number 10500000, Volvo #3459140. They made a small run on my request. Not cheap. Be aware there are numerous different cables based on your engine, etc.
My 480ES is black, manual trans, no AC, complete unmodified, no rust. Works well except the power windows which are non op. Need to solve that problem too. A black car without opening windows is a bit of an issue in sunny California!

WhiteWolf
Knows an Aerodeck isn't a 480
Posts: 272
Joined: Sat Dec 20, 2014 1:50 pm

Re: Changing accelerator cable

Post by WhiteWolf » Thu Mar 03, 2016 8:34 pm

Welcome...

When my cable snapped I learned the hard way..
Its easy enough to take out its getting it back in.. I found a piece of string pulled the new one through...
Anyway that piece needs a little turn to come off and that releases the hole to the firewall... The cable itself it attached to the pedal by a little plastic clip which pops in and out...
I attached the cable to the throttle body first then the pedal..
93 480 Turbo white
with Roboumod
91 480 Turbo white
with Roboumod..
91 480 Es silver

WhiteWolf
Knows an Aerodeck isn't a 480
Posts: 272
Joined: Sat Dec 20, 2014 1:50 pm

Re: Changing accelerator cable

Post by WhiteWolf » Thu Mar 03, 2016 8:35 pm

By the way I had to do it upside down... Head where the pedals are and feet near the roof..
It was a fun day
93 480 Turbo white
with Roboumod
91 480 Turbo white
with Roboumod..
91 480 Es silver

irollerdudek
480 Newbie
Posts: 11
Joined: Thu Mar 03, 2016 12:49 pm

Re: Changing accelerator cable

Post by irollerdudek » Fri Mar 04, 2016 5:18 am

Thanks for the info. I am used to working in the footwell upside down as I work a lot on vintage Volvo 1800's, still not fun as noted. So what tool did you use to turn the square to unlock it? I have tried a large screwdriver to pry on the corner, but it seems stuck. Maybe now that I know it is the way, I will apply more pressure. BTW, my interest in the 480ES is because I have an 1800ES, glass tailgates alike. My 2 ES's were pictured in Hemmings Sports and Exotics magazine last year, back to back with tailgates open.

balto8
Knows an Aerodeck isn't a 480
Posts: 239
Joined: Tue Jul 22, 2014 3:02 pm

Re: Changing accelerator cable

Post by balto8 » Fri Mar 04, 2016 6:24 pm

Jesus ! 170 eur for the cable !

http://www.skandix.de/en/spare-parts/en ... k/1050000/

I took one from a scrappy 1990 turbo a while ago looking to replace mine as the plastic body part is also waving goodbye. But then i found the cable end at the throttle valve was different. How can this be so?

The scrapyard fellow took the cable out for me undamaged in less than 5 minutes. Not saying this will be easy to refit. At least not in my useless hands.

Not spending 170 eur on the cable for now....

I do also also want some pics of the american ES. A way to reach 10 posts and be allowed to post pics is this. http://www.volvo-480-europe.org/forum/v ... 23&t=34848
1991 480 Black Turbo
2012 Seat Exeo ST
2013 VW Polo TSI DSG

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glasgowjim
480 Is my middle name
Posts: 4830
Joined: Sun Oct 01, 2006 5:28 pm
Location: GLASGOW SCOTLAND

Re: Changing accelerator cable

Post by glasgowjim » Fri Mar 04, 2016 6:28 pm

Perhaps a simple solution is to take a photograph of each end + one of the entire cable and post up or email me them as I have spare accelerator cables and can compare them with mine.

170 euro wow I have bought a complete 480 for less :roll:

irollerdudek
480 Newbie
Posts: 11
Joined: Thu Mar 03, 2016 12:49 pm

Re: Changing accelerator cable

Post by irollerdudek » Fri Mar 04, 2016 8:50 pm

Yes, I said it was expensive, but when the car is dead without it, and no known source, you bite and don't look back. BTW, it is not exactly like the original but looks like it should connect up ok. One concern is the square firewall mounting as it does not have a built in retainer like the original. But until I can get the old one out, I don't know how I will proceed.

Mike

WhiteWolf
Knows an Aerodeck isn't a 480
Posts: 272
Joined: Sat Dec 20, 2014 1:50 pm

Re: Changing accelerator cable

Post by WhiteWolf » Sat Mar 05, 2016 2:35 pm

All I had on me was a flat headed screwdriver.. I am sure I just prised it off.. I may have turned it half an inch I am not to sure....

Im sure I thought to myself I could bodge the whole thing again with a piece of wire or string..

Its good you have a 480 in America as it was intended for that market originally..
93 480 Turbo white
with Roboumod
91 480 Turbo white
with Roboumod..
91 480 Es silver

irollerdudek
480 Newbie
Posts: 11
Joined: Thu Mar 03, 2016 12:49 pm

Re: Changing accelerator cable

Post by irollerdudek » Mon Mar 21, 2016 3:13 am

Ok, having digested all the inputs I went out and changed the cable. Turns out the Skandix cable does have the same turn to lock mechanism on the firewall fitting. Thanks for the tip to turn it from the engine side. Other than being a bit awkward to get the tool on it, it did turn and when aligned with the square hole, I was able to pry it off with a strong thin scraper. Reinstall in reverse order was pretty easy once the square is pressed into the hole, it was a tight fit, then a 45 degree turn to lock it.

The Skandix cable is a bit different in a few ways.

It is better in that the firewall fitting is now metal and won't break like the original plastic one.

The pedal end hook is a metal piece instead of the original plastic snap in, but it doesn't have a retainer. It does have a groove that comes with a rubber ring in it, but I couldn't figure what it was for. I found a pin clip that would hold the J hook on the pedal rod. Not super secure, I would like a firmer lock, but will do for now until I find a better one.

It seems a bit short. Either the cable needs to be 10mm longer, or the sheath a bit shorter. With it adjusted to the longest position, it still holds the throttle 2 mm off the stop. Possibly the holding bracket is bent a bit, not sure.

It seems to work, but the battery had gone down, so I am charging it. Will then know how well it works and I can drive the car again! I took some pics of the new cable details and will post once I am enabled.

Mike D.
'73ES, '61P, '89ES + others

irollerdudek
480 Newbie
Posts: 11
Joined: Thu Mar 03, 2016 12:49 pm

Re: Changing accelerator cable

Post by irollerdudek » Mon Mar 21, 2016 3:49 pm

Oh, one more difference in the new Skandix cable. It does not have the 2 electrical contacts which open with WOT (pedal to the floor), so I assume those 2 wires need to be connected together and that function is lost. Not sure what it does, maybe to disable AC with WOT??

Mike D.
'73ES, '61P, '89ES + others

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jamescarruthers
480 Is my middle name
Posts: 2501
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: Changing accelerator cable

Post by jamescarruthers » Mon Mar 21, 2016 5:54 pm

Correct, it switches the A/C off at full throttle and changes the wipers from intermittent to constant, if selected intermittent
1987 Volvo 480 ES, 507274, 217 - Red (Ness)
2006 Citroen C6 Exclusive 3.0 petrol/LPG
2008 Mini Cooper convertible (Mau)

Previous 480's:
J123 CFU -- ES
J449 MNL -- ES auto
D864 CPV -- ES
L691 JFC -- Turbo
F70 MNR -- ES
H858 FGV -- Turbo auto
E981 KHM -- ES (509849)

mathrock
480 Newbie
Posts: 49
Joined: Sat Jan 05, 2019 2:57 pm

Re: Changing accelerator cable

Post by mathrock » Tue Feb 19, 2019 9:11 pm

irollerdudek wrote:
Fri Mar 04, 2016 5:18 am
BTW, my interest in the 480ES is because I have an 1800ES, glass tailgates alike. My 2 ES's were pictured in Hemmings Sports and Exotics magazine last year, back to back with tailgates open.
Found your cars! From here: https://www.hemmings.com/magazine/hsx/2 ... 47801.html

Image

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