Group:
Warranty Code:
Bulletin No.
Issue Date:

17 – Intake & Exhaust
051
SB - 09 - 003
06-10-2009

SERVICE INFORMATION BULLETIN
Subject:
SURGE WHILE DRIVING DURING AUTO REGENERATION
This bulletin provides a procedure to modify the Intake Throttle Valve.

1.

RELEVANT MODELS:
2008-2010 North American Production Vehicles equipped with the J08E engine.

2.

SYMPTOM / CONDITION:
Some 2008-2010 North American Production vehicles may exhibit a bucking or
a surge condition under heavy engine load or during DPR auto-regeneration. In
some cases the condition will be accompanied by a P0400 and or a P2101 DTC.
In the past it was necessary to replace the Intake Throttle Valve for this condition.
The following service procedure will resolve the condition without replacing the
Intake Throttle Valve assembly.

3.

PARTS REQUIRED:

4.

Part Number

Description

Quantity

S171712310

Gasket

1

PROCEDURE:

BEFORE YOU BEGIN
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Read and understand all instructions and procedures before you begin the work
Read and follow all WARNINGS set forth below
These alerts help to avoid damage to components, serious personal injury, or both
Park the vehicle on a level and solid surface
Apply the parking brake and confirm parking brake activation
Place wheel chocks in front of and behind all wheels
Use care when working around surfaces which may be hot
Wear safety glasses to prevent eye injuries
Properly calibrated torque wrenches must be used to prevent possible ensuing damage
Refer to any applicable Material Safety Data Sheet (M.S.D.S.) for additional information

Page 1

Vendor Ref: HMM-090521-W1

Group:
Warranty Code:
Bulletin No.
Issue Date:

17 – Intake & Exhaust
051
SB - 09 - 003
06-10-2009

SERVICE INFORMATION BULLETIN

a)

Remove two clamps and remove
Charge Air Cooler Outlet Hose.
Cover the Charge Air Cooler outlet
to prevent dirt from entering.

b)

Disconnect both Intake Throttle
Valve electrical connectors.

c)

Remove four Intake Throttle Valve
mounting bolts.

Page 2

Vendor Ref: HMM-090521-W1

Group:
Warranty Code:
Bulletin No.
Issue Date:

17 – Intake & Exhaust
051
SB - 09 - 003
06-10-2009

SERVICE INFORMATION BULLETIN
d)

Remove the Intake Throttle Valve
from the vehicle. Cover the Intake
Manifold opening to prevent dirt from
entering Intake Manifold.
Check and wiggle the throttle blade.
If any movement is detected between
the throttle blade and throttle shaft the
Throttle Valve assembly must be
replaced.

DO NOT ATTEMPT TO TIGHTEN THE SCREWS

e)

Refer to diagram # 2 on page 6 to
correctly locate hole placement. Insert a
shop rag on both sides of the throttle blade
stops as shown in diagram # 1 on page 6.
Center punch the three holes to locate
the correct location.

f)

Drill three 3mm holes in throttle blade at
the previously marked locations.

NOTE: Each Hole Size Must Be 3.0 mm

Page 3

Vendor Ref: HMM-090521-W1

Group:
Warranty Code:
Bulletin No.
Issue Date:

17 – Intake & Exhaust
051
SB - 09 - 003
06-10-2009

SERVICE INFORMATION BULLETIN

g)

Remove all burrs from the throttle
plate surface and clean all metal
shavings from Intake Throttle Valve
with compressed air before reassembly.

h)

Using the new gasket reinstall the
Intake Throttle Valve on the vehicle,
hand tighten the four bolts.

i)

Torque the four Intake Throttle Valve
bolts to their specified torque.

NOTE:
Specified Torque 21 lb. ft. (28,5 Nm)

Page 4

Vendor Ref: HMM-090521-W1

Group:
Warranty Code:
Bulletin No.
Issue Date:

17 – Intake & Exhaust
051
SB - 09 - 003
06-10-2009

SERVICE INFORMATION BULLETIN

j)

Reconnect both Intake Throttle Valve
electrical connectors.

k)

Reinstall Charge Air Cooler hose and
tighten the two clamps to the specified
torque.

NOTE:
Specified Torque 4.5 lb. ft. (6 Nm)

Page 5

Vendor Ref: HMM-090521-W1

Group:
Warranty Code:
Bulletin No.
Issue Date:

17 – Intake & Exhaust
051
SB - 09 - 003
06-10-2009

SERVICE INFORMATION BULLETIN
Diagram # 1: Intake Throttle Valve

DIAGRAMS

Hose insert side
Cushion
A

Drill this side

Drill direction

Diagram # 2: A-Section View

80

NOTE: If within warranty coverage
(2 years unlimited mileage) use the
following claim information:

5.

81

Shaft

CLAIM INFORMATION:
a) TSB No. 003-09
b) Time Allowance: 0.5 hr / Unit
c) Warranty code: 05171 T Code : 40
d) Operation code: 05150AOT
e) Original part No: 26100E0050

6.5

3-φ3
20°

Page 6

20°

Vendor Ref: HMM-090521-W1