2003 Ford F-150 Code set in cold weather

4.2L - MIL ON WITH DTC P1131 AND/OR P1151
TECHNICAL SERVICE BULLETIN
Reference Number(s): 05-22-6, Date of Issue: November 14, 2005
FORD:2001-2003 E-150, E-250; 2001-2004 F-150
Superceded Bulletin(s): 05-17-3, Date of Issue: September 5, 2005
Related Ref Number(s): 05-16-5, 05-17-3, 05-22-6
ARTICLE BEGINNING
DESCRIPTION
MIL ON WITH DTC P1131 AND/OR P1151 - 4.2L ENGINE
ISSUE
NOTE:This article supersedes TSB 05-17-3 to update the vehicle model years and 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.

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.
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.
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.

PARTS INFORMATION
PARTS INFORMATION
Part NumberPart Name
1L3Z-9H486-AAPort Gasket
3F2Z-9S479-AAIsolator Bolt

WARRANTY INFORMATION
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage.
WARRANTY INFORMATION
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