Crazyhoss

My 97 wont pass emissions here in CT. because the OBD2 states that my intake manifold runners are stuck in the open position. Mechanic states this is about a $1200 repair. Does anyone know the procedure for this fix? Thanks

obusnizzle

care to elaborate? what motor? something seems a bit odd, as none of that makes sense. There are no runners on a 2V Ford Modular Motor to be stuck open.

Crazyhoss

Yep, I have a 97 6 banger manual shift. Check engine light stays on and OBD2 says its an idle control problem attributed to the runners in the manifold being stuck open.
The truck occassionally idles badly when first started, but runs ok after a quick restert. Otherwise no problems idling.
The state wont allow it to pass emissions because of the trouble indicator, which I cleared once before and passed , but they've updated the system and can no longer get away with simply clearing the codes.

HiFlow5 0

What code is it throwing? That would help out a lot.

Crazyhoss

The code is P1538 ( Intake Manifold Runner stuck Open )

HiFlow5 0

After a little digging, it looks like its a valve similar to IAC's on older models. I found this site with someone having the same problem. There's also a link there in for a picture of what it looks like on the 6 banger.

http://www.ford-forums.com/ford-wind...tuck-open.html




I was going to look up the part and see how expensive it was, but I don't know the details on your truck.

Crazyhoss

Thanks for the research and pic. I also have been looking and from what I can tell, this is a very common problem but finding the fix is somewhat elusive. The pic you sent is a big help. I guess there's 2 valves and the biggest reported problem is leaky vacuum lines.
I bought a Haynes repair book today but so far it's not much help. Can't find anything regarding R&R of the manifold runner system.
I saw something about applying SeaFoam or some other cleaning solution into the valve linkage openings to help free evrything up, but I'm not sure of that yet.
I really appreciate the help everyone! Thanks.

NGM

Yea its a dual port engine. One set for torque and one for higher end hp. How did it work out for you?

ktmboyz

check to make sure the actuators are still connected to the levers.. I've seen alot of em just break the small white retaining clip in the lever where the actuator rod clips in.. If they are disconnected just make sure the levers will still turn, if they do get some new clips and try it.. If they are stuck and broke the clips then you'll prob have to pull the upper intake and clean the butterflies

tborgognoni

my 97 4.6 has an electric actuator located in bottom of lower intake behind water pump. have to remove intake manifold to replace cant see where it would cost more than a hundred dollars to do yourself