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Electronic Throttle Module (ETM) Replacement (25-149-E)

WARNING: This page is about the S80 T-6, which is a different variant/trim than selected.
Publication date: 2006-03-03
Reference number: 25-149-E

ELECTRONIC THROTTLE MODULE (ETM) REPLACEMENT

ELECTRONIC THROTTLE MODULE (ETM) REPLACEMENT

TECHNICAL SERVICE BULLETIN

Reference Number(s): 25-149-E, Date of Issue:  March 03, 2006
VOLVO: C70 1999-2002; S70 1999-2000; S60 2001-2002; V70 1999-2002; V70XC 1999-2001; S80 1999-2001
REFERENCE: VIDA TNN 25-149-A TNN 25-149-B
GROUP: 25
NO.: 149-E
Superceded Bulletin(s): 25-149-E, Date of Issue:  February 20, 2006
NOTE: This TNN supersedes TNN 25-149-E 02-20-06 showing the correction for the part numbers for the 5-cyl non-turbo Throttle Modules.

DESCRIPTION

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

S60 2001 V70 2001 V70XC 2001 5-cyl Turbo 

MATERIAL

Description Quantity Part Number
Throttle Module 1 8644347
Gasket 1 8636753
Cable tie 2 983662
Cable tie 3 983614
Cable tie(1) 2 983750
ETM reload, S60 2001 1 8645425
ETM reload, V70 2001 V70XC 2001 1 9494714
ECM gasoline upgrade 1 30677021
(1) Used if needed

C70 1999-2002 S70/V70 1999-2000 V70XC 1999-2000 5-cyl Turbo 

MATERIAL

Description Quantity Part Number
Throttle Module 1 8644347
Gasket 1 8636753
Cable tie(1) 2 983750
ETM reload, C70 1999-2002 1 9438425
ETM reload, S70/V70 1999-2000 V70XC 1999-2000 1 9438298
ECM gasoline upgrade, C70 1999-2002 1 30677000
ECM gasoline upgrade, S70/V70 1999-2000 1 30677005
V70XC 1999-2000
(1) Used if needed

S70 1999-2000 S60 2001-2002 V70 1999-2002 5-cyl Non-turbo 

MATERIAL

Description Quantity Part Number
Throttle Module (S60 2001-2002 V70 2001-2002) 1 8644344
Throttle Module (S70 V70 1999-2000) 1 8644347
Gasket 1 8636753
Cable tie(1) 2 983750
ETM reload, S70 1999-2000 V70 1999-2000 1 9438298
ETM reload, S60 2001-2002 1 8645425
ETM reload, V70 2001-2002 1 9494714
ECM gasoline upgrade, S70 1999-2000 V70 1999-2000 1 30677005
ECM gasoline upgrade, S60 2001-2002 V70 2001-2002 1 30677021
(1) Used if needed

6-cyl Turbo 

MATERIAL

Description Quantity Part Number
Throttle Module 1 8644347
Gasket 1 8636753
Cable tie(1) 2 983750
ETM reload, S80 1 9438290
ECM gasoline upgrade 1 30677021
(1) Used if needed

6-cyl Non turbo 

MATERIAL

Description Quantity Part Number
Throttle Module 1 8644347
Gasket 1 8636753
Cable tie(1) 2 983750
ETM reload, S80 1 9438290
ECM gasoline upgrade 1 30677021
(1) Used if needed

    Throttle Module replacement 5-cyl Turbo S60 2001 V70 2001 V70XC 2001 

  1. Detach the battery cable from the negative battery terminal. See:

    Electrical system

    Battery replacement

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

    Fig 1: View Of Charge Air Hose
    G04600765Courtesy of VOLVO CARS OF NORTH AMERICA.

    Remove: 

    • dipstick guide tube
    • charge air hose from intercooler.
    • charge air pipe from rubber connection on turbocharger.

    Remove the charge air pipe and charge air hose.

  3. 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.

    Fig 2: Removing Fan Cowling
    G04600766Courtesy of VOLVO CARS OF NORTH AMERICA.
  4. 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).

    Fig 3: Locating Charge Air Pipe Clamp
    G04600767Courtesy of VOLVO CARS OF NORTH AMERICA.
  5. 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.

    Fig 4: Locating Nuts & Bolt Of Starter Motor Bracket
    G04600768Courtesy of VOLVO CARS OF NORTH AMERICA.

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

    Fig 5: Locating Electronic Throttle Module Screws
    G04600769Courtesy of VOLVO CARS OF NORTH AMERICA.
  7. Installing the electronic throttle module (ETM) 

    Install: 

    • the new electronic throttle module (ETM) with new gasket
    • the 4 screws until they make contact.
      Fig 6: Locating Electronic Throttle Module Screws
      G04600770Courtesy of VOLVO CARS OF NORTH AMERICA.

    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.
    Fig 7: Locating Nuts & Bolt Of Starter Motor Bracket
    G04600771Courtesy of VOLVO CARS OF NORTH AMERICA.

  8. 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.

  9. Attach the charge air hose to the electronic throttle module (ETM) and tighten the clamp.
    Fig 8: Locating Charge Air Hose Clamp
    G04600772Courtesy of VOLVO CARS OF NORTH AMERICA.
  10. 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.

    Fig 9: Securing Cable Harness At Fan Cowling
    G04600773Courtesy of VOLVO CARS OF NORTH AMERICA.

    Fit the EVAP-valve.

    Plug in the electric cooling fan connectors.

  11. 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.
      Fig 10: View Of Charge Air Hose
      G04600774Courtesy of VOLVO CARS OF NORTH AMERICA.
  12. Install: 
    • dipstick guide tube

    Turn the ignition key to position 2.

    Connect the battery cable to the negative battery terminal.

  13. Ordering and downloading software 
    NOTE: After ETM reload the ECM must be upgraded.

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

  14. 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 5-cyl Turbo C70 1999-2002 S70/V70 1999-2000 V70XC 1999-2000 

  15. Detach the battery cable from the negative battery terminal.

    Remove the dipstick guide tube.

  16. 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).

    Fig 11: Locating Charge Air Pipe Clamp
    G04600775Courtesy of VOLVO CARS OF NORTH AMERICA.
  17. Remove: 
    • the intake manifold between the front and air filter housing.
      • Fig 12: Removing Intake Manifold
      G04600776Courtesy of VOLVO CARS OF NORTH AMERICA.
    • 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.
  18. 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.

    Fig 13: Locating Nuts And Bolt Of Starter Motor Bracket
    G04600777Courtesy of VOLVO CARS OF NORTH AMERICA.

  19. Remove the 4 electronic throttle module (ETM) screws.

    Fig 14: Locating Electronic Throttle Module Screws
    G04600778Courtesy of VOLVO CARS OF NORTH AMERICA.
  20. Installing the electronic throttle module (ETM) 

    Install: 

    • the new electronic throttle module (ETM) with new gasket
    • the 4 bolts until they make contact.
      Fig 15: Locating Electronic Throttle Module Screws
      G04600779Courtesy of VOLVO CARS OF NORTH AMERICA.

  21. 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.

    Fig 16: Locating Nuts And Bolt Of Starter Motor Bracket
    G04600780Courtesy of VOLVO CARS OF NORTH AMERICA.

    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.
  22. 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.

  23. Install: 

    • the fan cowling with its 4 bolts
      • Fig 17: Installing Fan Cowling
      G04600781Courtesy of VOLVO CARS OF NORTH AMERICA.
    • 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.
  24. 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).

    Fig 18: Locating Charge Air Pipe Hose Clamp
    G04600782Courtesy of VOLVO CARS OF NORTH AMERICA.
  25. Install: 
    • dipstick 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.

  26. Ordering and downloading software 
    NOTE: After ETM reload the ECM must be upgraded.

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

  27. 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 5-cyl Non-turbo S70 1999-2000 S60 2001-2002 V70 1999-2002 

    NOTE: The method applies to only replacing the throttle module for the S70 1999-2000 S60 2001-2002 V70 1999-2002 5-cyl Non-turbo
  28. Remove:
    • the battery negative lead from the battery. When removing and installing the battery leads. See:

      Electrical system

      Battery replacement

  29. Remove: 
    • the intake pipe between the front cover plate and the air cleaner.
    • the intake pipe between the air cleaner.
      Fig 19: Locating Intake Pipe
      G04600783Courtesy of VOLVO CARS OF NORTH AMERICA.

  30. Remove: 

    • the 4 electronic throttle module (ETM) screws.

    Disconnect the electronic throttle module (ETM) connector

    Fig 20: Locating Electronic Throttle Module Screws
    G04600784Courtesy of VOLVO CARS OF NORTH AMERICA.
  31. 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.

    Pull the electrical cable for the electronic throttle module (ETM) forward from in back of the starter motor bracket.

    Fig 21: Locating Nuts And Bolt Of Starter Motor Bracket
    G04600785Courtesy of VOLVO CARS OF NORTH AMERICA.
  32. Installing the electronic throttle module (ETM) 

    Install: 

    • the new electronic throttle module (ETM) with new gasket
    • the 4 bolts and tighten to 10 Nm..
      Fig 22: Locating Electronic Throttle Module Bolts
      G04600786Courtesy of VOLVO CARS OF NORTH AMERICA.

  33. 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.
    Fig 23: Locating Nuts And Bolt Of Starter Motor Bracket
    G04600787Courtesy of VOLVO CARS OF NORTH AMERICA.

  34. Install: 

    • the intake pipe between the air cleaner and the electronic throttle module (ETM).
    • the intake pipe between the air cleaner and the front cover plate.
      Fig 24: Locating Intake Pipe
      G04600788Courtesy of VOLVO CARS OF NORTH AMERICA.

  35. Turn the ignition key to position 2.

    Connect the battery cable to the negative battery terminal.

  36. Ordering and downloading software 
    NOTE: After ETM reload the ECM must be upgraded.

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

  37. 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 Turbo 

  38. 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.
      Fig 25: Removing Charge Air Hose From Charge Air Pipe
      G04600789Courtesy of VOLVO CARS OF NORTH AMERICA.
  39. 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.

    Fig 26: Removing Overflow Valve From Charge Air Hose
    G04600790Courtesy of VOLVO CARS OF NORTH AMERICA.

  40. 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.

    Fig 27: Locating Charge Air Pipe Clamp
    G04600791Courtesy of VOLVO CARS OF NORTH AMERICA.
  41. 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.

    Fig 28: Locating Nuts And Bolt Of Starter Motor Bracket
    G04600792Courtesy of VOLVO CARS OF NORTH AMERICA.

  42. Remove the 4 electronic throttle module (ETM) bolts.

    Fig 29: Locating Electronic Throttle Module Bolts
    G04600793Courtesy of VOLVO CARS OF NORTH AMERICA.
  43. Installing the electronic throttle module (ETM) 

    Install: 

    • the new electronic throttle module (ETM) with new gasket
    • the 4 bolts until they make contact.
      Fig 30: Locating Electronic Throttle Module Bolts
      G04600794Courtesy of VOLVO CARS OF NORTH AMERICA.

  44. 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.
    Fig 31: Locating Nuts And Bolt Of Starter Motor Bracket
    G04600795Courtesy of VOLVO CARS OF NORTH AMERICA.

  45. 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.

  46. Installing the charge air pipe 

    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).

    Fig 32: Locating Charge Air Pipe Clamp
    G04600796Courtesy of VOLVO CARS OF NORTH AMERICA.

  47. 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.

    Fig 33: Installing Overflow Valve To Charge Air Hose
    G04600797Courtesy of VOLVO CARS OF NORTH AMERICA.

  48. Install: 

    • dipstick 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.

    Fig 34: Installing Charge Air Hose To Charge Air Pipe
    G04600798Courtesy of VOLVO CARS OF NORTH AMERICA.
  49. Ordering and downloading software 
    NOTE: After ETM reload the ECM must be upgraded.

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

  50. 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 

  51. Remove: 

    • the battery cable from the negative battery terminal. See:

      Electrical system

      Battery replacement.

    • dipstick guide tube.

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

    Fig 35: View Of Intake Manifold
    G04600799Courtesy of VOLVO CARS OF NORTH AMERICA.
  53. 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.

    Fig 36: Locating Nuts And Bolt Of Starter Motor Bracket
    G04600800Courtesy of VOLVO CARS OF NORTH AMERICA.

  54. Remove the 4 electronic throttle module (ETM) bolts.

    Fig 37: Locating Electronic Throttle Module Bolts
    G04600801Courtesy of VOLVO CARS OF NORTH AMERICA.
  55. Installing the electronic throttle module (ETM) 

    Install: 

    • the new electronic throttle module (ETM) with new gasket
    • the 4 bolts until they make contact.
      Fig 38: Locating Electronic Throttle Module Bolts
      G04600802Courtesy of VOLVO CARS OF NORTH AMERICA.

  56. 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.
    Fig 39: Locating Nuts And Bolt Of Starter Motor Bracket
    G04600803Courtesy of VOLVO CARS OF NORTH AMERICA.

  57. Install: 

    • intake manifold between the electronic throttle module (ETM) and air filter
    • dipstick guide tube.
      Fig 40: View Of Intake Manifold
      G04600804Courtesy of VOLVO CARS OF NORTH AMERICA.
  58. Finishing work 

    Turn the ignition key to position 2.

    Connect the battery cable to the negative battery terminal.

  59. Ordering and downloading software 
    NOTE: After ETM reload the ECM must be upgraded.

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

  60. 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.

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