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  #1  
Old 02-26-2011, 08:30 AM
jjarrett96 jjarrett96 is offline
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Default Intake Manifold Runner Stuck Open

I thought I'd share this. I have a 2003 Ranger XLT, 4 cylinder. I got an error code (P2004). It said Intake Manifold Runner Stuck Open Bank 001. I found a little black hose (1/8 inch ID) that was busted thanks to a post on youtube

I cut the busted part out and slid it back on the elbow fitting. The error code went away.

I've attached some photos.
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  #2  
Old 05-05-2011, 09:36 AM
BikerBones BikerBones is offline
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Default Re: Intake Manifold Runner Stuck Open

Okay everyone, I've been getting a code P2004 for a few months now.

I drive a 2003 Ford Ranger 2.3 liter.

Every time I erase the code it comes back within a quarter mile of driving.

I looked everywhere on the internet to show exactly where this part was located to no avail...

I drove to my local dealership and they pointed it out to me right away along with the vacuum lines that just fell off the module...

The module is made of metal and plastic with one (1) electrical connectors on the bottom and on the back and two (2) vacuum lines connected by a plastic connector on the front of the module connected to the IMRC by crimped metal tabs on the metal housing of the module...

The metal component of the IMRC has rusted considerably and the plastic housing that the vacuum lines connect to were crimped to the metal housing.

So, when the metal housing rusted away the crimped metal holding the plastic part that the vacuum lines connect to failed and fell off.

Below is an actual photo of the rusted part and the vacuum lines that fell off.

The metal crimped areas are circled in red...

CLICK IMAGE FOR LARGER IMAGE
.

So, I'm posting these images to hopefully help others looking for this part.

I've circled the part in red in the images below.

Cost was 127.00 + 8.58 in taxes

Total 135.58

Should only take a whole 5 to 10 minutes to replace.

CLICK IMAGE FOR LARGER IMAGE
.

CLICK IMAGE FOR LARGER IMAGE
.

Hopefully this post helps someone...

The images above will stay for as long as I own my website where they are located...

(Since I cannot upload the images here...)

Respects,
-Bones

++++++++++++++++++++
'03 Ford Ranger
'06 Harley Davidson 1200 XL Custom
'03 Harley Davidson 883 XL Custom <- Wife's Bike
++++++++++++++++++++
Ride to Live, Live to Ride.
Support your local MC.

Last edited by BikerBones; 05-09-2011 at 07:16 AM.
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  #3  
Old 05-06-2011, 10:00 AM
BikerBones BikerBones is offline
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Default Re: Intake Manifold Runner Stuck Open

Here is an updated image after I replaced the IMRC.

Took me all but 5 minutes to do this.

CLICK IMAGE FOR LARGER IMAGE
.

AND upon further inspection of the old part and the new part, the plastic piece where the vacuum hoses were attached was NOT held on by crimped metal tabs. The crimped metal tabs were holding on the metal end which held the plastic piece in place. The plastic piece that the vacuum hoses were attached to was broke at the top and bottom. (The only places it could break.) Very bad design in my opinion.

In my opinion the cause for the plastic piece to fail was because of the rust. The rust expanded and caused the plastic to fail and break from stress.

Here is two images of the old rusted, broken IMRC after removal.

You can clearly see in the images below where the plastic failed and broke. Circled in red.

CLICK IMAGE FOR LARGER IMAGE
.

You can also see how the rust built up and expanded and obviously caused the part to fail.

CLICK IMAGE FOR LARGER IMAGE
.



This was one of the easiest fixes I have ever had to do on this truck.

Here is how I did it.

1. Disconnected the negative cable from the battery.
+
- 8mm bolt on my 2003 Ford Ranger
- Losen slightly, twist and pull the negative cable off.

2. Removed the 8mm bolt from the IMRC.
+
- The bolt was slightly rusted but I was easily able to
- force the 8mm socket on and remove the bolt from the plastic
- intake manifold.

3. Unplugged the electrical connector from the old IMRC.
+
- Gently so as to not break the tab off the electrical
- connector, pull the tab outward with your fingernail or
- a small screwdriver and pull gently on the plug not
- the wires.

4. Unplugged the vacuum hoses from the plastic on the IMRC.
+
- Gently twist and pull the vacuum hoses off the IMRC one
- by one. Pull the front one off first then the lower.
- It is very important to remember which hose is which.
- Thoroughly inspect the vacuum hoses for cracks and breaks.

I reversed this procedure to install the new IMRC.

Too easy...

Respects,
-Bones

++++++++++++++++++++
'03 Ford Ranger
'06 Harley Davidson 1200 XL Custom
'03 Harley Davidson 883 XL Custom <- Wife's Bike
++++++++++++++++++++
Ride to Live, Live to Ride.
Support your local MC.

Last edited by BikerBones; 05-09-2011 at 07:18 AM.
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  #4  
Old 05-06-2011, 10:02 AM
DiabloBlanco DiabloBlanco is offline
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Default Re: Intake Manifold Runner Stuck Open

very nice biker!
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  #5  
Old 05-07-2011, 08:14 AM
BikerBones BikerBones is offline
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Default Re: Intake Manifold Runner Stuck Open

Here is what some of the dealerships said when I called and asked them for an estimate of how much it would cost to have my IMRC put on my truck. Nothing else just labor on installing the IMRC. I was specific.

One dealership in Kent, Ohio named Klaben Ford told me on the phone about 1 hour labor, approx. $120 USD

Another dealership in Cuyahoga Falls, Ohio named Spitzer Ford told me 2.8 hours labor, approx. $240 USD. They said they would have to remove the plenum/manifold to replace the IMRC. Then they said they would have to re-program the computer as well. He said he does it all the time and has done many... LOL I've never done this before and I did it in my driveway in 5 minutes. Didn't have to remove the plenum. Didn't have to re-program the computer. The check engine light went out as soon as I started the truck. Truck runs like new now. Smooth. Beautiful.

Another dealership in Tallmadge, Ohio named Park Ford told me 1.5 to 2 hours labor, approx. $146.

A few points to remember...

1. I'm not an ASE certified mechanic...

2. I don't have a big shop or all the expensive tools like the mechanics at the dealerships.

3. I don't have a book telling me how to do the job.

4. I don't work on vehicles for a living.

5. I don't claim to be an expert or a professional auto mechanic

6. I have cheap Craftsman tools, not MAC or SNAP ON.

Just because these so called experts have a uniform with their names embroidered on them and buy expensive tools, doesn't mean they are truthful, professionals who just want to help you. They are, in actuality, ASE certified con artists. 90% of the time they will make you believe you need more work than you actually need and that the job will take a lot longer than it actually should.

Don't get me wrong, just because you learned something on the internet doesn't mean you're an expert and it doesn't mean the mechanic doesn't know what they're talking about. However, just because the shop foreman tells you something doesn't mean he is telling you the truth either. They're out to make money and that is the prime mover of their struggle, the root of all evil. MONEY. Remember that...

Do your homework. Call around. Get estimates. Talk to the mechanics. Read a book. Educate yourself, it won't hurt...

Respects,
-Bones

++++++++++++++++++++
'03 Ford Ranger
'06 Harley Davidson 1200 XL Custom
'03 Harley Davidson 883 XL Custom <- Wife's Bike
++++++++++++++++++++
Ride to Live, Live to Ride.
Support your local MC.

Last edited by BikerBones; 05-09-2011 at 07:18 AM.
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  #6  
Old 05-07-2011, 02:40 PM
jjarrett96 jjarrett96 is offline
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Default Re: Intake Manifold Runner Stuck Open

That's a good diagram. Item 9Y445 is the hose that cracked on mine. Mine wasn't rusted like yours. It's good to know it's an easy fix if the whole thing needs replaced. Thanks for sharing the info.
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  #7  
Old 05-07-2011, 04:53 PM
mickblock mickblock is offline
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Default Re: Intake Manifold Runner Stuck Open

get her DONE buddy!!!! Beautiful post.
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  #8  
Old 05-08-2011, 08:05 PM
2ZZGE05 2ZZGE05 is offline
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Default Re: Intake Manifold Runner Stuck Open

Quote:
Originally Posted by jjarrett96 View Post
That's a good diagram. Item 9Y445 is the hose that cracked on mine. Mine wasn't rusted like yours. It's good to know it's an easy fix if the whole thing needs replaced. Thanks for sharing the info.
Same here. Stupid hose that runs through the runners cracked in two places on mine. The way it's routed is horrible lol

Thanks for this thread. This helped me turn off my CEL thats been bugging me for a while now. I got a lil longer hose and routed it on the outside of the runners. The heat from the motor seems to crack it.
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  #9  
Old 05-09-2011, 06:48 AM
BikerBones BikerBones is offline
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Default Re: Intake Manifold Runner Stuck Open

Thanks everyone, much appreciated.

I had the man at the parts counter at the dealership print that diagram out for me because I couldn't find anything like that on the internet.

So, I came straight home scanned it and posted it in like 5 forums. LOL

Hopefully my posts will help someone save time and money.

Respects,
-Bones

++++++++++++++++++++
'03 Ford Ranger
'06 Harley Davidson 1200 XL Custom
'03 Harley Davidson 883 XL Custom <- Wife's Bike
++++++++++++++++++++
Ride to Live, Live to Ride.
Support your local MC.

Last edited by BikerBones; 05-09-2011 at 07:18 AM.
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  #10  
Old 05-09-2011, 09:45 AM
DiabloBlanco DiabloBlanco is offline
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Default Re: Intake Manifold Runner Stuck Open

Dman man thats some serious stuff. Good job!
__________________
YZ the way to be!
The Brotherhood!

Mods to come: Camburg entry 6.0 system. FiberwerkX Fenders and bedsides. Tube bumper.
R.I.P. Jeff Ashton. 1992-2011
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  #11  
Old 07-08-2011, 04:25 PM
gh0strider18 gh0strider18 is offline
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Default Re: Intake Manifold Runner Stuck Open

Really useful post thanks a million! My trouble is I can't not find a definite answer from anyone, are there 2 imrc valves on the 2.3 i4? I've checked the one that is shown in the diagram and helpfully pointed out in the video up top of the post, and it seems ok?! The hose coming up from the bottom doesn't seem cracked. Is it worth it to take the imrc off and attempt to clean it? Any help will and is much appreciated...
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  #12  
Old 07-09-2011, 04:43 PM
gh0strider18 gh0strider18 is offline
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Default Re: Intake Manifold Runner Stuck Open

Ok for anybody else that gets the same engine code, before you order The new IMRC take off the bottom facing hose and check it...I found a crack about 1/4 inch down from the imrc. I just cut the hose...rerouted the hose a little and refitted it back on. Check engine light went off immediately

I agree with others, terrible design as the hose is sure to crack after some time...I have a 2003 so 8 great years out of it
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  #13  
Old 09-20-2011, 05:38 PM
rjbaker rjbaker is offline
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Default Re: Intake Manifold Runner Stuck Open

bottom hose on the imrc valve is connected, i cant find where it plugs in on the engine any help would be great!
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  #14  
Old 09-24-2011, 01:48 PM
gh0strider18 gh0strider18 is offline
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Default Re: Intake Manifold Runner Stuck Open

Quote:
Originally Posted by rjbaker View Post
bottom hose on the imrc valve is connected, i cant find where it plugs in on the engine any help would be great!
Me either!! I got the code again and after refitting a new vacumn line to the old I accidentally pulled out the tube that goes to the bottom of IMRC at the engine...no idea where it plugs in as I can't see it well...any help would be much appreciated.
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A.R.E topper - Led 3rd brake light - Led 4th brake light (tailgate bar) - Blue Led footwell lighting - Auxilary back up lights - Aftermarket yellow fog lights - Maglight Mod - more to come!
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  #15  
Old 09-24-2011, 03:28 PM
gh0strider18 gh0strider18 is offline
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Default Re: Intake Manifold Runner Stuck Open

Found it, next to the wire harness above the IMRC it's like impossible to see, but it's there, you may want to remove the harness for an easier fitting.
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