Article No. 03-16-1

DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTCS) P0171/P0174 STORED IN MEMORY-VEHICLES EQUIPPED WITH 3.8L ENGINE

MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED WITH DIAGNOSTIC TROUBLE CODES (DTCS P0171/P0174 STORED IN MEMORY -

VEHICLES EQUIPPIED WITH 3.8L ENGINE

FORD: 1999-2003 WINDSTAR

This TSB supersedes 03-4-7 and 00-21-8

ISSUE: Some vehicles may exhibit a check engine light on and lean Diagnostic Trouble Codes (DTC's) P0171/P0174 (system too

lean bank 1 0r 2) stored in memory.

Action: Do not replace PCM (Powertrain Control Module), MAF (Mass Air Flow), or HEGO's (Heated Oxygen Sensors),as these parts

are not the root cause of the lean codes conditions described. Refer to the following Service Procedure for details.

SERVICE PROCEDURE: These conditions may be caused by a loose fitting on the fuel pressure regulator vacuum line on the

intake manifold end and /or leaking isolator blots/port gaskets in the lower upper intake manifold mounting area. This

condition is sometimes intermittent and may not be apparent on warmed-up engine.

If the vacuum line from the intake manifold to the fuel pressure regulator is loose at the manifold (due to oil

contamination), replace the vacuum line (9E498) and install a new design LH service valve cover (6582). Another vacuum leak

source is the gasket (9H486) between the upper and lower intakek manifold assemblies caused by a loss of tension at the

isolator bolt assemblies (9S479) due to contamination of the rubber grommets from excessive oil pullover.

1. Perform self test, if codes P0171, P0174 are the only codes stored in the PCM then continue with this article.

For any other codes, follow the normal diagnostic procedures found in the PC/ED Manual.

2. (ALL 19999-2003). Reprogram the PCM (Powertrain Control Module) with the latest calibration, WDS B26.2 release

or later. Do not replace the PCM. Reset the Keep alive memory.

3. (1999-2001 ONLY). Inspect the vacuum line from the intake manifold to the fuel pressure regulator for

looseness, leaks and /or oil contamination and replace Vacuum Line (XF2z-9E498-DD) if required.

4. (1999-2000 ONLY). Inspect the Lh Valve Cover, it should be a (3F2Z-6582-BA) Install a new LH Valve Cover if

required, refer to Workshop Manual Section 303-01 Valve Cover-LH. (REfer to the following NOTE for description of the old

style valve cover).

NOTE
USING A SHOP LIGHT OR FLASHLIGHT, CHECK THE LH VALVE COVER TO SEE IF IT HAS ALREADY BEEN UPDATED TO THE LATEST LEVEL. REMOVE

THE PCV VALVE AND RUBBER GROMMET FROm THE VALVE COVER AND LOOK THROUGH THE HOLE AT THE INTERNAL SHEET METAL BAFFLE. THE OLD

STYLE VALVE COVER BAFFLE HAS A 3/16" DIAMETER HOLE IN THE 5:00 O'CLOCK POSITION AS YOU LOOK THROUGH THE PCV HOLE. VALVE

COVERS FITTING THIS DESCRIPTION MUST BE REPLACED.

5. (ALL 1999-2003). Remove the upper intake and replace only port gaskets (9H486) and isolator bolt assemblies

(9S479). The new isolator bolt assemblies use a rubber material that is green in color, do not use the old isolator bolt

assemblies with the black rubber material (XF2Z-AA). Do not replace any other parts (black or aluminum) or the lower intake

gaskets, (9439 and 9A424/425) or the upper intake clamshell gasket (9461). Refer to Workshop Manual Section 303-01, Intake

Manifold-Upper.

6. (ALL 1999-2003). 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.

OTHER APPLICABLE ARTICLES: NONE

SUPERSEDES: 00-21-8, 03-4-7

WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Coverage And Emissions

Warranty Coverage

Here's a link too. If you go to this link you'll get a lot of pop ups, but it shows you scanned copies of the Technical Service Bullentin TSB 03-16-1

http://members.fortunecity.com/donkeytrader/TSB_03-16-1.html

Will FORD pay for this fix if the check engine light is on and those codes are showing up ?

Avalonjohn