Fulltext TSBs

Technical Service Bulletins

TSB
05-22-6
  • MIL ON WITH DTC P1131 AND/OR P1151 – 4.2L ENGINE
Publication Date: October 21, 2005

FORD:
2001-2003 E-150, E-250
2001-2004 F-150

This article supersedes TSB 05-17-3 to update the vehicle model years and issue.

ISSUE:

Some 2001-2003 F-150, 2004 F-150 Heritage and 2001-2003 E-150/250 vehicles equipped with a 4.2L engine may exhibit the malfunction indicator lamp (MIL) on with diagnostic trouble codes (DTCs) P1131 and/or P1151 (system too lean bank 1 or 2). This condition may be due to leaking isolator bolts/port gaskets in the upper-to-lower intake manifold mounting area. This condition is sometimes intermittent and may not be apparent on a warmed-up engine.

ACTION:

Refer to the following Service Procedure.

SERVICE PROCEDURE

NOTE:THIS CONDITION COULD ALSO BE DUE TO WARM AMBIENT TEMPERATURES AND THE USE OF WINTER GRADE FUELS WHICH HAVE VERY HIGH VOLATILITY AND MAY BOIL IN THE FUEL LINES (VAPOR LOCK) DURING A SHORT HOT SOAK. OXYGENATED FUELS WILL AGGRAVATE THIS CONDITION. IF NON-OXYGENATED FUEL IS NOT AVAILABLE, USE MID/HIGH OCTANE FUELS WHICH HAVE LOWER VOLATILITY AND MAY HELP ALLEVIATE THE CONDITION.

  1. Perform a self test. If DTC P1131 and/or P1151 are the only codes stored in the powertrain control module (PCM) proceed to Step 2. If any additional DTCs are present, follow normal diagnostic procedures found in the PC/ED Manual.
  2. Remove the upper intake and replace only the port gaskets (9H486) and isolator bolt assemblies (9S479). The new isolator bolt assemblies use a rubber material that is green in color, do not install the old isolator bolt assemblies with the black rubber material. Do not replace any other intake parts or gaskets. Refer to Workshop Manual, Section 303-01 (In-Vehicle Repair; Upper Intake Manifold) for removal and installation procedure.
  3. While the upper intake manifold is removed, check the exhaust gas recirculation (EGR) orifices that are pressed into each primary port of the lower intake manifold. If any of the orifices are plugged with soot, clean and unplug them with a pick and solvent.

    CAUTION:DO NOT USE SMOKE DETECTION, PROPANE GAS, CARBURETOR OR BRAKE CLEANER TO TEST FOR VACUUM LEAKS. CARBURETOR OR BRAKE CLEANER MAY CAUSE INTAKE MANIFOLD RUNNER CONTROL (IMRC) BEARING FAILURE. SOME LEAKAGE FROM THE IDLE AIR CONTROL (IAC) OR EGR VALVE AND IMRC SEALS IS NORMAL, DO NOT REPLACE THESE PARTS. DO NOT REPLACE THE LOWER ALUMINUM INTAKE MANIFOLD.


PART NUMBERPART NAME
1L3Z-9H486-AAPort Gasket
3F2Z-9S479-AAIsolator Bolt

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage

OPERATIONDESCRIPTIONTIME
052206A2001-2004 F-150 4.2L: Check For Diagnostic Trouble Codes, Replace Gasket Between Upper And Lower Intake, And Clean EGR (Do Not Use With 6007A1, 6007A2, 6007A5, 6007A14, 6149A, 6584A, 6584AT, 6020A, 12650D, 12650D35, 8005A, 10346A, 9438A, 9424A1)1.8 Hrs.
052206B2001-2003 Econoline 4.2L: Check For Diagnostic Trouble Codes, Replace Gasket Between Upper And Lower Intake, And Clean EGR (Do Not Use With 6007A1, 6007A2, 6007A5, 6007A14, 6149A, 6584A, 6584AT, 6020A, 12650D, 12650D35, 8005A, 10346A, 9438A, 9424A1)2.0 Hrs.

DEALER CODING

BASIC PART NO.CONDITION CODE
9424D8

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company’s on-line technical resources.

Copyright © 2005 Ford Motor Company