NOOB with '96 Windstar 3.8 IMRC and vacuum issues
tigger4x
10-10-2010, 05:31 PM
First post here after using the search feature and not finding more precise answers. My '96 Windstar 3.8L has approx. 150K on it and I'm the 2nd owner. The first codes I encountered were to replace the O2 sensors. The next codes were about misfire in cylinder 4; of which I replaced the spark plugs, original wires, PCV, and the 4th sylinder injector. After all that it failed and I had to replace both cats. Now I'm getting a code about Bank 1 being stuck open aka the IMRC stuck. I found that BOTH of the IMRCs were missing the plastic retainers and the actuator rods weren't even attached. I couldnt find the retainers so I reattached the rods with E-clips. I did a hard reset of the computer by disconnecting the negative battery cable. Once reattached We went for a drive and it seemed to run okay for a little while. Then the CEL came on and I was noticing the stumbling being more pronounced than before. I did some research in this forum and I'm trying to figure out wat I read. I'm most likely going to buy both IMRCs from Rock Auto (http://www.rockauto.com/catalog/raframecatalog.php?a=G-autoparts) because of the missing retainer clips on the actuator rods and they are the orginal parts AND they are MUCH cheaper than the McParts stores! I'm not so good at reading and understanding how to diagnose the vacuum and electrical. :screwy: I see where the connections are on the IMRCs, but havent been able to really see where they go behind the Bank 1 intake manifold against the firewall. I'm feeling more and more convinced that I have a vacuum issue. I cant seem to locate the red and whites vacuum lines for purchase; or the unit that supplies the vacuum. Maybe its going overboard to replace it all, but I'm sick of playing footsie with this thing! I'm also wondering if I should replace the other 5 injectors as they are the originals as well. IF they should be replaced should I just pony up for all 6 so they match to avoid any cross manufacturer issues?
Sorry so long winded, I'm trying not to leave anything out. :runaround:
Sorry so long winded, I'm trying not to leave anything out. :runaround:
Freakzilla69
10-10-2010, 06:58 PM
The vacuum is supplied by a solenoid on the back of the upper intake manifold.
You can buy vacuum hose at the parts store but you probably won't find it in red.
You can buy vacuum hose at the parts store but you probably won't find it in red.
wiswind
10-12-2010, 07:14 PM
There is a windstar link in my signature that takes you to a bunch of pictures of my '96 3.8L windstar.
I have a good close-up picture of the IMRC actuator and linkage in there someplace.
Injectors, I don't think you need to buy new injectors, they are quite reliable.
HOWEVER, on my '96, I needed to run a can of Berryman's B-12 Chemtool evey now and then to clean up the injectors.
I tried a BUNCH of different cleaners and that is the ONLY one that cleaned the injector deposits that I would get.
Otherwise, no problem with the injectors.
IMRC and rough running.....
Take note that 1996 through 1998 IMRC is vaccum driven......1999 and newer is electrical driven.
If they are inoperative, I would fasten them in the CLOSED position.
The springs in the shafts hold them OPEN, and the actuators pull them closed, using vaccum from the IMRC control solenoid.
You could plug the vaccum line, and fasten them BOTH closed.
You will STILL get the Check Engine Light (CEL) and a code, but the motor will run smooth and you will get better fuel economy with them closed then you would with them OPEN.
There are a number of vaccum lines coming off the back side of the upper intake manifold.
One goes to the IMRC vaccum control solenoid and then to BOTH of the IMRC actuators.
The PCM (computer) controls the IMRC by sending a electrical signal to the IMRC vaccum control solenoid.
Rough running, dirty fuel injectors, vaccum leak, spark plugs (use the correct Double Platinum Motorcraft or Autolite brand), spark plug wires or coil pack.
The wrong spark plug can cause misfire issues right out of the box, particularly those multi-prong plugs.
Spark plug wires, if old.....get a new set.
Coil pack, there is 1 block with 3 coils inside.......all the spark plug wires connect to it.
Vaccum leak, lots of possibilities, PVC vaccum line.....starts at the TOP of the upper intake manifold, next to the throttle body, goes back to the REAR valve cover.
The flexible elbow on the top of the upper intake manifold is likely to develop a crack....but also follow the line all the way to the PCV valve and make sure that it is in good shape.
Does the air inside the vehicle go ONLY to the windshield (defrost) regardless of what you select?, If so.....there is a vaccum leak as this driven by vaccum from the motor.
With no vaccum to the airflow select (floor, dash vents or defrost) the system will be in the defrost mode.
How old is the fuel filter?, located under the car.....kind of in front of the rear, driver's side tire, inside side of the unibody "frame" member.
I have a good close-up picture of the IMRC actuator and linkage in there someplace.
Injectors, I don't think you need to buy new injectors, they are quite reliable.
HOWEVER, on my '96, I needed to run a can of Berryman's B-12 Chemtool evey now and then to clean up the injectors.
I tried a BUNCH of different cleaners and that is the ONLY one that cleaned the injector deposits that I would get.
Otherwise, no problem with the injectors.
IMRC and rough running.....
Take note that 1996 through 1998 IMRC is vaccum driven......1999 and newer is electrical driven.
If they are inoperative, I would fasten them in the CLOSED position.
The springs in the shafts hold them OPEN, and the actuators pull them closed, using vaccum from the IMRC control solenoid.
You could plug the vaccum line, and fasten them BOTH closed.
You will STILL get the Check Engine Light (CEL) and a code, but the motor will run smooth and you will get better fuel economy with them closed then you would with them OPEN.
There are a number of vaccum lines coming off the back side of the upper intake manifold.
One goes to the IMRC vaccum control solenoid and then to BOTH of the IMRC actuators.
The PCM (computer) controls the IMRC by sending a electrical signal to the IMRC vaccum control solenoid.
Rough running, dirty fuel injectors, vaccum leak, spark plugs (use the correct Double Platinum Motorcraft or Autolite brand), spark plug wires or coil pack.
The wrong spark plug can cause misfire issues right out of the box, particularly those multi-prong plugs.
Spark plug wires, if old.....get a new set.
Coil pack, there is 1 block with 3 coils inside.......all the spark plug wires connect to it.
Vaccum leak, lots of possibilities, PVC vaccum line.....starts at the TOP of the upper intake manifold, next to the throttle body, goes back to the REAR valve cover.
The flexible elbow on the top of the upper intake manifold is likely to develop a crack....but also follow the line all the way to the PCV valve and make sure that it is in good shape.
Does the air inside the vehicle go ONLY to the windshield (defrost) regardless of what you select?, If so.....there is a vaccum leak as this driven by vaccum from the motor.
With no vaccum to the airflow select (floor, dash vents or defrost) the system will be in the defrost mode.
How old is the fuel filter?, located under the car.....kind of in front of the rear, driver's side tire, inside side of the unibody "frame" member.
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