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  #16  
Old 02-16-2011, 07:33 PM
range0rover range0rover is offline
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Default Re: Fluctuating Low and Very High Idle

do you think the 2.5 4cyl would also have this shaft? I'm trying to track down the cause of a p0171 also.
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  #17  
Old 03-04-2011, 01:04 AM
srcash srcash is offline
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Default Re: Fluctuating Low and Very High Idle

I gotta think probably so, but I'm not too sure. It's been a little while now, if I remember right that is a lean code; I would check vacuum lines first, on the 2.3 there is a line that comes down and turns sharp going into a vacuum solenoid or valve which I think (consequently) controls that variable inlet shaft. That line tends to break right at the connection because of that bend, the 2.5 might have the same issue, I really don't know. Point being, look very carefully at the lines - all the way through. If you're not sure about a line, you could always disconnect it and put a vacuum gauge on the end farthest from the intake, or use a finger to plug it while it's running (you should also hear it hissing in that case, if it's otherwise intact). After that, I'm all about the starter fluid (or other flammable aerosol type fluid) method. Spray down any potential suspect areas while it's running, you should hear a noticeable RPM change when you find the leak, in my case, the engine shook a bit more when I was on the spot, and that was more noticeable than the RPM change. Check any mating surfaces (near gaskets) and anything with a seal on the intake, from the throttle body - back. Good luck!
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  #18  
Old 03-04-2011, 05:34 PM
BT24 BT24 is offline
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Default Re: Fluctuating Low and Very High Idle

Check the hose that goes from the intake manifold to the fuel rail regulator...the tube is only about 3 or 4 inches long. I was getting P0300, P0301 and P0302 codes intermittently. I found the hose was completely clogged. The other tube referred to in the above post is connected to the throttle body and then a a metal tube bolted to the intake manifold..it then goes back to a rubber tube that runs to the evap components. That little tube is hidden underneath the intake manifold. Mine was corroded and causing your issues. It really has to be a vacuum problem as far as I am concerned
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  #19  
Old 11-26-2011, 07:59 PM
lemmy lemmy is offline
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Default Re: Fluctuating Low and Very High Idle

I know this is an old post, but I figured it might help someone. I have the same issue Scrash is talking about. I am trying to figure out how to make a plug, or just try to buy a used intake. It looks like the shaft has wallowed out the hole a bit, that is why I am a bit worried about just putting something in there to seal it. Maybe what used to be in there actually supported the end of the shaft a bit. Here are some pics of what he is talking about.
Attached Images
File Type: jpg intake1.jpg (72.8 KB, 17 views)
File Type: jpg intake2.jpg (41.9 KB, 18 views)
File Type: jpg intake3.jpg (58.9 KB, 17 views)
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  #20  
Old 11-27-2011, 06:17 PM
srcash srcash is offline
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Default Re: Fluctuating Low and Very High Idle

Wow!! That's it! I'm glad I'm not totally crazy (although I'm sorry for the luck), and someone else was able to find the same problem. That thing looks really bad, I'd think a replacement is definitely in order, I'm not sure that a plug would allow the variable inlet to work properly, probably causing other drive-ability issues and codes. This also makes me think that perhaps I should chat back with the owner of the one I worked on - as I recall I think he ended up having another code within a few days. I didn't realize - until seeing your pictures - that end indeed and obviously needs a support of some kind with perhaps some kind of bearing and seal to allow it to rotate / operate smoothly - and not wallow out as it has in your case. I wish these manufacturers would get their heads out and design new ideas to last for longer than the trip off the lot! Good luck!
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  #21  
Old 11-28-2011, 07:36 AM
lemmy lemmy is offline
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Default Re: Fluctuating Low and Very High Idle

Yeah, this looks like a really bad design. I have a used one on the way, I am thinking of covering the plug in some sort of epoxy to keep whatever it is from coming out. I found another guy on another forum that had this problem as well.
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  #22  
Old 11-29-2011, 08:25 AM
lemmy lemmy is offline
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Default Re: Fluctuating Low and Very High Idle

srcash,

I found more information about these swirl valve/imrc. Apparently in the UK they had major issues with them on the 1.8 and 2.0L Duratec engines. By late 2002 they had fixed the problem. But I would think this issue is probably why they got rid of them on the 2004+ 2.3L engines.

Quote:
The problem is that each butterfly has relatively small moulded-in bearing bushes at the ends, and over time these wear away. Once the bushes are worn through, the long square steel spindle that runs the length of the manifold (to connect the butterfly plates to the vacuum actuator) also starts to wear away at the points it touches the manifold tube walls, and eventually breaks at one or more of these points.
http://www.fordwiki.co.uk/index.php?...ault_-_Duratec

Some good pictures at the bottom of that article. I almost just plugged the hole and put it back on. After reading that I am glad I didn't. It sounds like it would wallow out that hole more and put more stress on the other side of the support and ultimately break off. I ordered a used 2004 intake off of ebay, but after I purchased it I realized that 2004+ don't have IMRC anymore. So I ended up going to Ford and buying a new one for $277.
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