Fuel System - Electronic Throttle Module Replacement

NO: 25-149E

DATE: 12-06-2005

MODEL/YEAR:
C70 1999-2002
S70 1999-2000
S60 2001-2002
V70 1999-2002
V70XC 1999-2001
S80 1999-2001

SUBJECT:
Electronic Throttle Module (ETM) Replacement

REFERENCE:
VIDA, TNN 25-149-A, TNN 25-149-B

DESCRIPTION:

This TNN describes an update of the existing method for Electronic Throttle Body (ETM) replacement. Replacement must always be preceded by fault-tracing according to VIDA and TNN 25-149-A.

Material/Parts

Throttle body replacement 5-cyl turbo S60/V70 (00-)/V70XC (01-)/S80

Detach the battery cable from the negative battery terminal. See: Electrical system Battery replacement

Remove the charge air pipe bolts from the intake manifold across the engine.

Remove:

- dip stick guide tube

- charge air hose from intercooler.

- charge air pipe from rubber connection on turbocharger.

Remove the charge air pipe and charge air hose.

Removing the fan cowling

Remove the intake manifold to the air filter housing.

Detach both connectors of the electric cooling fan.

Remove:

- EVAP valve to electric cooling fan from fan cowling

- the four cable ties holding the cable harness in place at the fan cowling.

Note!
Some cars have three cable ties and a clip to hold the cable harness in place at the fan cowling.

Lift the expansion tank hoses out of the holes at the top edge of the fan cowling. Remove both bolts holding the fan cowling in place.

Carefully raise the electric cooling fan.

Removing the electronic throttle module (ETM)

Loosen the hose clamp of the charge air pipe on the electronic throttle module (ETM). Remove the charge air pipe from the electronic throttle module (ETM).

Caution!
Do not cut the electrical cable to the electronic throttle module (ETM). It may be necessary to return the electronic throttle module (ETM) assembly.

If the electric cable of the electronic throttle module (ETM) is behind the starter motor bracket:

Slacken the two nuts. Remove the bolt.

Remove any cable ties and unplug the electronic throttle module (ETM) connector. Pull the electrical cable of the electronic throttle module (ETM) forward from the back of the starter motor bracket.

Remove the 4 x screws for the electronic throttle module (ETM).

Installing the electronic throttle module (ETM)

Install:

- the new electronic throttle module (ETM) with new gasket

- the 4 screws until they make contact.

Route the electrical cable for the electronic throttle module (ETM) behind the starter motor bracket.

Fit the bolt in the engine block. Tighten the two nuts and the bolt. Plug in the connector and install the cable tie.

Note!
If the cable was not routed behind the starter motor bracket, fasten the cable along the cable duct using two strip clamps.

Raise the car.

Remove the cover from below the engine.

Tighten the 4 electronic throttle module (ETM) screws. Tightening torque 10 Nm.

Install the cover below the engine.

Lower the car.

Attach the charge air hose to the electronic throttle module (ETM) and tighten the clamp.

Installing the fan cowling

Carefully lower the fan cowling and align it with the retainers. Route the cable harness behind the retainer (3).

Tighten the two retaining bolts. Press down the hose from the expansion tank into the retainer on the fan cowling. Use cable ties (1) and (2) to secure the cable harness at the fan cowling. See illustration. Fit the EVAP-valve.

Plug in the electric cooling fan connectors.

Install:

- the charge air hose/charge air pipe between the intercooler and the rubber connection on the turbocharger

- the two charge air pipe bolts on the intake manifold

- the intake manifold to the air filter housing

- the intake manifold between the front and air filter housing.

Install:

- dip stick guide tube Turn the ignition key to position 2.

Connect the battery cable to the negative battery terminal.

Ordering and downloading software

Note!
After ETM reload the ECM must be upgraded.

Order and download software for ETM reload and ECM gasoline upgrade.

Finishing work

Check that no diagnostic trouble codes were stored in the control module during repair work.

Test drive the car and check the functionality of the engine.

Detach the battery cable from the negative battery terminal.

Remove the dipstick guide tube.

Removing the electronic throttle module] (ETM)

Loosen the hose clamp of the charge air pipe on the electronic throttle module (ETM). Remove the charge air pipe from the electronic throttle module (ETM).

Remove:

- the intake manifold between the front and air filter housing.

- the four bolts holding the fan cowling cover in place.

Move the cover aside slightly, pull up on the relay holder and unplug the fan connectors.

Remove:

- the charge air hose from the intercooler

- hoses and electrical cables from their retainers

- the two electric cooling fan relays from the fan cowling by bending the relays in toward the engine compartment and pulling up.

Open the cable ties of the electrical cables.

Remove:

- the connectors with retainers on both sides of the fan cowling

- the EVAP valve from the fan cowling

- the fan with cowling

Caution!
Do not cut the electrical cable to the electronic throttle module (ETM). It may be necessary to return the electronic throttle module (ETM) assembly.

If the electric cable of the electronic throttle module (ETM) is behind the starter motor bracket:

Slacken the two nuts. Remove the bolt.

Remove any cable ties and unplug the electronic throttle module (ETM) connector. Pull the electrical cable for the electronic throttle module (ETM) forward from in back of the starter motor bracket.

Remove the 4 electronic throttle module (ETM) screws.

Installing the electronic throttle module (ETM)

Install:

- the new electronic throttle module (ETM) with new gasket

- the 4 bolts until they make contact.

Route the electrical cable from the electronic throttle module (ETM) behind the starter motor bracket.

Fit the bolt in the engine block. Tighten the two nuts and the bolt. Plug in the connector and install the cable tie.

Note!
If the cable was not routed behind the starter motor bracket, fasten the cable along the cable duct using two strip clamps.

Raise the car.

Remove the cover from below the engine.

Tighten the 4 electronic throttle module (ETM) bolts. Tightening torque 10 Nm.

Install the cover below the engine.

Lower the car.

Install:

- the fan cowling with its 4 bolts

- the connector retainer before the lower bolt on the fan cowling's (car's) left side is inserted. Tighten the lower bolts. Insert the 2 upper bolts.

- the fan connectors

- the electric cooling fan relay in the holder

- the EVAP valve to the fan cowling

- the connector with retainer on the right side of the fan cowling

- cable ties around electrical cables

- hoses and electrical cables in their retainers/clips

- the charge air hose to the intercooler

- the relay holder and tighten the upper bolts.

Installing the charge air pipe

Install the charge air pipe to the electronic throttle module (ETM).

Tighten the hose clamp of the charge air pipe on the electronic throttle module (ETM).

Install:

- dip stick guide tube

- the intake manifold between the front and air filter housing.

Turn the ignition key to position 2. Connect the battery cable to the negative battery terminal.

Ordering and downloading software

Note!
After ETM reload the ECM must be upgraded.

Order and download software for ETM reload and ECM gasoline upgrade.

Finishing work

Check that no diagnostic trouble codes were stored in the control module during repair work.

Test drive the car and check the functionality of the engine.

Remove:

- the battery cable to the negative battery terminal. See: Electrical system Battery replacement.

- the intake manifold between the front and air filter housing

- the charge air hose from the charge air pipe and move it aside

- dipstick guide tube.

Unplug the two connectors from the charge air hose between the intercooler and electronic throttle module (ETM). Open the hose clamp.

Remove the overflow valve from the charge air hose.

Loosen the hose clamp of the charge air pipe on the electronic throttle module (ETM) and intercooler.

Remove the charge air pipe from the electronic throttle module (ETM) and intercooler.

Caution!
Do not cut the electrical cable to the electronic throttle module (ETM). It may be necessary to return the electronic throttle module (ETM) assembly.

If the electric cable from the electronic throttle module (ETM) is behind the starter motor bracket:

Slacken the two nuts. Remove the bolt.

Remove any cable ties and unplug the electronic throttle module (ETM) connector. Pull the electrical cable from the electronic throttle module (ETM) forward from in back of the starter motor bracket.

Remove the 4 electronic throttle module (ETM) bolts.

Installing the electronic throttle module (ETM)

Install:

- the new electronic throttle module (ETM) with new gasket

- the 4 bolts until they make contact.

Install the charge air pipe to the electronic throttle module (ETM) and intercooler. Tighten the hose clamp of the charge air pipe on the electronic throttle module (ETM).

Plug in the two connectors of the charge air hose between the intercooler and electronic throttle module (ETM).

Fit the overflow valve to the charge air hose with the clamp.

Install:

- dip stick guide tube

- the charge air hose to the charge air pipe

- the intake manifold between the front and air filter housing

Turn the ignition key to position 2. Connect the battery cable to the negative battery terminal.

Ordering and downloading software

Note!
After ETM reload the ECM must be upgraded.

Order and download software for ETM reload and ECM gasoline upgrade.

Finishing work

Check that no diagnostic trouble codes were stored in the control module during repair work.

Test drive the car and check the functionality of the engine.

Electronic Throttle Module (ETM) replacement 6-cyl non turbo

Remove:

- the battery cable from the negative battery terminal. See: Electrical system Battery replacement.

- dip stick guide tube.

Remove the intake manifold between the electric throttle module (ETM) and air filter.

Caution!
Do not cut the electrical cable to the electronic throttle module (ETM). It may be necessary to return the electronic throttle module (ETM) assembly.

If the electric cable from the electronic throttle module (ETM) is behind the starter motor bracket:

Slacken the two nuts. Remove the bolt.

Remove any cable ties and unplug the electronic throttle module (ETM) connector. Pull the electrical cable for the electronic throttle module (ETM) forward from in back of the starter motor bracket.

Remove the 4 electronic throttle module (ETM) bolts.

Installing the electronic throttle module (ETM)

Install:

- the new electronic throttle module (ETM) with new gasket

- the 4 bolts until they make contact.

- intake manifold between the electronic throttle module (ETM) and air filter

- dipstick guide tube.

Finishing work

Turn the ignition key to position 2. Connect the battery cable to the negative battery terminal.

Ordering and downloading software

Note!
After ETM reload the ECM must be upgraded.

Order and download software for ETM reload and ECM gasoline upgrade.

Finishing work

Check that no diagnostic trouble codes were stored in the control module during repair work.

Test drive the car and check the functionality of the engine.