I've decided to tackle changing the oil seal on the PCV system this weekend. While I have the intake manifold off I am going to cleam the ETM. Any suggestions on these jobs would be helpful. I have picked up some useful tips from other postings on this site but any further suggestions would be helpful. I have the O Ring and gasket.

Don't use carburetor cleaner; try to find "throttle body cleaner" or "fuel injection cleaner" as the solvents are not as harsh.

A Volvo service bulletin I saw (attached) described gently cleaning all contaminated surfaces with throttle body cleaner and a soft bristle brush. The flat rate times for the work indicate a cost of about $100 at a reasonable dealer.

Cleaning the PCV system is a great idea because oil vapours seem to be a source of throttle body contamination. However, it may be in your best interests not to touch the ETM because it is under warranty. If you clean it, could you be accused of damaging it?

The use of synthetic oil may aid in keeping the PCV system and the the ETM clean.

Thanks AlbertF, being in New Zealand we are not covered by the USA/Canada 10year warranty offered by Volvo so there is no danger of voiding the warranty, the car is well out of the standard 3 year warranty.

Anyway I have the inlet manifold and ETM off. The manifold bolts were refeshingly accesible. The fiddly bits were removing all those vauum hoses...there seems to be a huge number of them. Some were difficult to remove as the had gone stiff and brittle with age and the heat. I have labelled the ones where the might be some confusion. The cable cladding is incredibly brittle and just shatters as you move it around.

The ETM looks quite dirty. There is a yellow glazed film on the throttle body and the valve. In addition there is general carbon/oil grime around the edges of the valve. In terms of cleaning solvent I have only found the concentrated fuel injector cleaner that you add to your fuel tank...I assume this is not what you were meaning AlbertF? Can anyone confirm this for me.

Will be tackling the PCV O Ring tomorrow.

By the way ...I have been using the following useful post as a guideline for this job

http://www.volvo-forums.com/index.php?show...indpost&p=14604

Hi Graeme

Visit this link

http://www.vexedvolvo.org/

The click on technical information

You will see detailed ETM assembly.

In addition to cleaning the throttle unit bore on the pdf file that albertf has provided. You might want to consider cleaning the wipers and resistance film housed inside the left and right end caps. See fig. 2, 4, 5 & 7.

Scandinavian Motors are not willing to clean this part and they would rather replace te entire ETM unit.

I would not bother removing the front cover in fig. 3 as there are no moving parts inside here.

I have a spare discarded ETM donated by SM which I hope to let my mechanic practise on first if my ETM decides to throw a hissy fit one day.

Let us know your progress.

Good luck

Thanks. I am still weighing up my options on the ETM. Should I just clean the throttle body or go further as you suggest. The Vexed Volvo site provides some very good instructions. I have another option I am going to look at tomorrow. Will keep you posted on that.

Got the PCV out. What a mess ...looks like 6 years of oil and grime built up. It was really grotty down there. Took the opportunity for a decent cleanup. I have ordered a new PCV box...about $USD50. Got some photos which i will load later.

Will fit it later this week and put it all back together once I have decided what to do with the ETM.

Poopbunny,

I'm happy to clean the throttle body myself, but am unsure about cleaning the internals.

Whats your thought on cleaning the wipers and resistance film? What would you use to clean it? I am concerned that it could make the problem worse. Your thoughts please.

Graeme

Hi Graeme

At this point I would seek the advice of Don Willson of VexedVolvo.

I don't think the cleaning that is critical (as long as non-corrosive substances are used) but what you may want to lubricate it with after (if any).

After all the main problem is the wearing caused by the pressure of the wipers on the resistance film.

I was thinking along the lines of either
- SPG (Special Grease Plastic) by Electrolube
or maybe a Teflon based lubricating aerosol (that will not eat plastic)
- CRC 808 Silicone spray.

Re-sealing the end caps is also important.

Let me know if you would like to have a crack at the discarded ETM that I have.

If I were you, I would go ahead and change the PCV oil trap itself. This the black platic box you have to take off to replace the oring behond it. I bought one for around $25. The old one that came off was full of oil and sludge. After I changed my PCV oil trap and seal and cleaned my ETM, my 2000 S80 T6 runs great! Good luck! :57:

Thanks Mikeys...yes I'll be replacing the PCV itself. In fact I'm picking it up today for install tonight. I spoke to Don from Vexed Volvo and here is is view on what to clean and not clean on the ETM.

"Don't try opening the ETM up if you do not have a spare. The pot is not dirty, it is worn out. Cleaning will not help, unless as reassembling it you moved the wipers just enough to get the in a fresh area but even then I would expect that they would fall back into the same ruts."

Given this advice I am simply going to clean the throttle body and re-intsall.

Sorry, I haven't checked this thread for a few days.

I just read a Popular Mechanics article on cleaning throttle bodies. The author explained that a harsh solvent and vigorous brushing will remove a coating that is intended to reduce contaminant buildup. He suggested that if one is unable to find throttle body cleaner, a 5:1 mixture of gasoline and fuel injection cleaner might be a good alternative. The leftover solution can simply be poured into the fuel tank.

Obviously, disconnecting the battery and banishing all smokers are essential.

Thanks AlbertF, I was just talking to the Volvo guys and they reccomended the following...

saBesto "Carburettor and throttle plate cleaner" manuifactured by Wurth which is german company.

I have picked up a can when I got the PCV so will clean tonight and let you know how it goes.

I have fitted the new PCV box. Gave the ETM throttle body a decent clean. The stuff I mentioned above is pretty good. It's looking pretty clean, although I am sceptical how this might minimise the problem of throttle surge at low revs. Still I hope it does! Need to buy about a dozen jubilee clips tomorrow to re-connect all those vacuum hoses. The main issue with this job is that a lot of teh hoses are brittle and difficult to get. Be patient and careful and budget on a few breakages. Will keep you posted on what difference it made if any.

Here are some photos on progress...

Job done. Just took it for a test drive and it runs nice. No more oil leak and hopefully a few more km's out of the ETM before the inevitable. Not a difficult job just fiddly...beats the hell out of the Oil Pan O Ring job.

Parts:

PCV O Ring US$15
Inlet gasket US$15
PCV unit US$60

No special tools apart for the fuel line quick disconnect tool which was pretty cheap.

Any questions let me know. I have a couple more photos which I'll load Monday.