Cleaning the Electronic Throttle Module (ETM), 5-Cyl Non-Turbo

Remove:





- the battery negative lead, see:

Electrical system Battery replacement

- the intake hose between the front and air cleaner (ACL) housing

- the charge air hose from the charge air pipe

- the oil dipstick pipe.

The banjo nipple is located underneath the intake manifold, behind the mounting for the oil dipstick pipe.





Disconnect both the connectors from the charge air hose between the charge air cooler and electronic throttle module (ETM).

Remove:

- the hose clamps

- the by-pass valve from the charge air hose.





Remove the hose clamp for the charge air pipe on the electronic throttle module (ETM) and the charge air cooler (CAC). Remove the charge air pipe from the electronic throttle module (ETM) and the charge air cooler (CAC).





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





Place paper between the fan shroud and the engine block.
Place the electronic throttle module (ETM) on the paper.

Cleaning the ETM

Warning!
DO NOT submerge throttle unit in cleaning solvent. ONLY use cleaning solvent recommended in this TNN.

Important!
Do not scrape or use a rotary wire brush to clean the unit.

Clean the ETM bore using cleaner (P/N 11 61 828) and a soft bristle brush.





Ensure that all the residue is removed from the shaded surfaces shown in the illustration.





Carefully wipe the inside of the bore clean on both sides of the throttle disc. Wipe clean the edge of the throttle disc.

Do not use compressed air to dry the throttle module.

Cleaning the crankcase ventilation





Remove the banjo bolt from the intake manifold.

Remove the hose (1) from the banjo nipple. Remove the oil filler cap.

Blow the hose clean (1) using compressed air (2) to verify that the system is open. If the hose is blocked clean the hose using 2.0 mm diameter wire.

If air travels through to the oil filler the breather is good, no further verification or repairs are necessary.

Note!
If the hose is blocked, use a welding rod (maximum diameter 2.0 mm, approximately 250 mm long) to unblock the hose.

Clean the banjo nipple using a diameter 2.0 mm drill bit (3).

Install:

- the hose on the banjo nipple

- the banjo bolt with new gaskets

- the oil filler cap.

Raise the car.

Remove the splashguard under the engine

Tighten the banjo bolt. Tighten to 24 Nm.

Tighten the 4 x screws for the electronic throttle module (ETM). Tighten to 10 Nm.

Install the cover under the engine.

Lower the car.

Installing the electronic throttle module (ETM)





Install:

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

- the 4 x screws for the electronic throttle module (ETM). Tighten to 10 Nm.

Installing the charge air pipe





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

Tighten the hose clamps for the charge air pipe on the electronic throttle module (ETM).

Install:





- both the connectors from the charge air hose between the charge air cooler and electronic throttle module (ETM).

- the by-pass valve to the charge air hose with clamp.

Install:





- the oil dipstick pipe

- the charge air hose to the charge air pipe

- the intake hose between the front and air cleaner (ACL) housing.

Finishing work

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