1998 1800 avensis inlet manifold vacuum fix

[fixitphil]

I have over a few years noticed a gradual lack of pulling power/gutless.  Last mot mentioned engine seemed to be throttling back???. I have noticed that the vacuum actuator for the inlet manifold run butterfly control does not pull in when vacuum is present at start/normal revs <4,200 rpm.  Also vacuum was being lost less than -20 inHg say -17inHg. I tested the vacuum supply to the vacuum actuator alone with the actuator out of vacuum cicuit.   I read -21 inHg excellent, no losses so far. I then tested the actuator at the input pipe, no vacuum could be held. Device bust. As I could not source a new one without spending a lota dosh, I decided to try and fix the old one. This took a few hours but is so far running OK. I have attached images of the method and materials I used. I made the four clamping clips from 2mm thick mild steel  measuring 20mm x 15mm. I put a slot in one of the long sides of the piece to create a a strong push on clip. I used 4 hacksaw blades side by side to create a slot approx 2mm wide and 7mm deep to create the slot. When pushed on to the assembly flanges to clamp together,if not tight enough I used a small hammer to peen the metal around the slot to reduce the slot width. I have entitled the images to help clarify process. To fix the split I used the part of a nitrile rubber glove as a support for the general application of the black silicon rubber gasket solution(LOCTITE 5910). I did not glue the mended diaphragm in to the chamber, I just used the compressive fit when the clips are forced on. After testing the device I araldited the areas around the clips(4) to prevent movement.

All as good as gold.   Best of luck to anyone who is as tight as me.

fixitphil

[Konrad C]

Great post Philip (fixitphil). I assumed you saw this recent post with the same issue? - 

I will link your post to Stephen's. Two different fixes to the same problem. If I still owned my old Avensis, I would has used either idea.

[steve mezzle]

Excellent job!