Professional Documents
Culture Documents
ETM Retrofit
ETM Retrofit
Figure 1 Vishay Throttle Position Sensor prior to modification for Magneti Marelli retrofit. With
some modification (cut off the mounting flange) this sensor fits well in the center area of the ETM
end plate.
Figure 3 All work is done without disassembly of ETM. End plates are modified some to accept new
sensor and wiring. If anyone has attempted to disassemble one of these ETMs youll know why its a
big benefit not to have to do disassembly.
Figure 5 New sensor does add some width to end plate dimensions.
Figure 6 Vishay sensor housing is cut and shaped to fit center opening of end plate. Magnet is
removed from original Vishay sensor housing/holder and directly installed on end of throttle plate
shaft. Aligning and reliably attaching magnet to the shaft end was the biggest challenge in this
project. Small magnet size of the Vishay sensor was one of the primary reasons to go with this sensor.
Figure 7. Air gap between magnet and sensor IC is adjusted by filing sensor outer housing.
Figure 8 Sensor wiring soldered to exposed contact areas of end plate. No disassembly of ETM is
required with this method. Output signal is also routed to other side, which replaces the second
sensor output. Note cut in end plate contacts just above the soldered wires; the cut disconnects signal,
power and ground from original sensor.
Figure 9 Throttle position signal is required for both sides. Originally, ETM has two sensors for
redundancy and safety. New (and single) sensor output signal is supplied to both sides.
Figure 11 Retaining bracket was made to hold sensor in place. Silicone is also used for sensor
adhesion and sealant once voltage adjustments are completed. Wires are protected with high temp
split wire loom.
Figure 12 High temp epoxy is used for protection once wires are soldered to exposed contact area.
Page 43 provides the best information Ive found on the different ETM failure modes and
the associated emergency running modes with the Bosch Motronic system. Volvo
emergency running modes may be different then whats in the Audi link referenced but
the Motronic system is similar.
http://www.ibiblio.org/tkan/audi/2.7Biturbo-SelfStudy.pdf