Intake-to-Throttle Body Joint May Cause A Whistle-Like Sound On 3.7L Engines

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NUMBER: 09-001-07
GROUP: Engine
DATE: March 14, 2007

SUBJECT:

Intake-to-Throttle Body Joint May Cause A Whistle-Like Sound On 3.7L Engines

OVERVIEW:

This bulletin involves applying a thin bead of RTV to the intake manifold-to-throttle body joint.

MODELS:

NOTE: ** This bulletin applies to vehicles equipped with a 3.7L engine (sales code EKG) built on or before March 12, 2007 (MDH 0312XX). **

SYMPTOM/CONDITION:

The customer may experience a slight ** high frequency (pitch) ** whistle-like sound while driving. This sound is not loud and may not be noticed by most drivers. The sound can occur at any ambient or engine operating temperature. The whistle-like sound is most noticeable under load, with a light throttle, and between 1,200 and 2,000 engine RPM’s.

NOTE: ** Very few vehicles will exhibit this condition. **

DIAGNOSIS:

If the customer experiences the above condition perform the Repair Procedure.

PARTS REQUIRED:

Qty.	Part No.	Description
1	04883971	Engine Sealant RTV Silicone Rubber Adhesive (one tube will do 15 vehicles)

REPAIR PROCEDURE:

Disconnect and isolate the negative battery cable from the battery.
Remove the Electronic Throttle Control (ETC) throttle body from the intake manifold. For detailed service information refer to TechCONNECT, select the Service Info tab > 14 – Fuel System > Fuel Injection – Gas > Throttle Body > Removal or Installation > Throttle Body – 3.7L.
Apply a very small diameter bead (1 mm) of RTV to the intake manifold-to-throttle body joint. The RTV is to be applied to the lower section of the joint between the lower two throttle body bolt attachment holes ( 1). A very small amount of RTV is needed to seal the slight space/gap on the inner surface of the joint. The gap was created by a slight taper in the intake manifold joint surface.

NOTE: Do not apply an excessive amount of RTV to the joint.

Fig. 1 INTAKE-TO-THROTTLE BODY JOINT

1 – Intake Manifold
2 – Intake-to-Throttle Body Gasket
3 – Apply Very Small Diameter Bead Of RTV Between Two Lower Bolt Holes
4 – Two Lower Bolt Holes

NOTE: Over-torque of the throttle body attaching bolts may cause damage to the throttle body.

Install the ETC throttle body to the intake manifold. Tighten the throttle body four attaching bolts to 7 Nm (60 in. lbs.).

NOTE: Wipe off inside joint of any excess RTV squeeze-out.

Reassemble the remaining engine components.
Connect the negative battery cable to the battery. Set the clock to the correct time.

POLICY:

Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No:	Description	Amount
09-50-01-96	Manifold, Intake – Apply RTV to the Intake Manifold-to-Throttle Body Joint (B)	0.5 Hrs.

FAILURE CODE:

ZZ	Service Action

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-009-06, DATED SEPTEMBER 09, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF A CLEAN POINT IN THE MODELS SECTION.