1996 Windstar IMRC code 1537

[ruggratt]

Had the check engine light on in my Windstar so I went to Autozone to get the code read. It came up:

P1537 Intake Manifold Runner Control Open (Bank 1)

Went home and looked under hood and was able to move both levers by hand. They moved independently of each other by hand. Started car and revved engine. The back IMRC lever moved when it revved higher then 3000 rpm but the front didn't move. Went to eat dinner, came back and tried the same thing again and now neither moves, maybe because engine was cold? Anyhow I pulled the vacuum lines on each and only the front one has vacuum. So my questions are:

1.) Is bank number one the one closest to the front of the car or closest to the firewall?

2.) Assuming bank number one is the one near the firewall (rear), why did only that one move and not the front one? And why would I have the code saying it's open if it appears to be moving?

or

3.) If bank number one is the front bank, could the lack of vacuum to cause bank number 2 not to open? I'm confused because the back opened before but now neither opens.

4.) I assume since the front one has vacuum and the back one does not that they do not share a vacuum source? I could not trace the lines very far as they went under the cowling and it was getting dark. Does anyone know where the lines end, what I mean is where is the vacuum source?

5.) Are there any other conditions that must be met for them to open? I was under the impression that both opened at 3000 rpm or higher. Earlier when the van was hot the rear opened when I revved engine, when cold neither opened. Is this normal?

Thank for any help you can give me...

Dave

[lilvinny]

without getting into too much detail the rods connected from lever to the actuator usually fall of the clips break and are sold seperate from your dealer. bank one is the rear and the reason you saw it move was because it possibly is not connected to the actuator there for the intake air was moving the lever

[ruggratt]

Originally Posted by lilvinny

without getting into too much detail the rods connected from lever to the actuator usually fall of the clips break and are sold seperate from your dealer. bank one is the rear and the reason you saw it move was because it possibly is not connected to the actuator there for the intake air was moving the lever

You are correct that the clips are broken/rotted away however the linkages are still attached. So if bank one is the rear then should I assume that the rear actuator controls that rear bank? Or is it the front one that I never saw move?

[lilvinny]

the rear does control the rear.the actuator also acts as a sensor so if that rod is not connected to both lever and actuator it will trip the code for not seeing closed voltage.both banks are independent so really don't be too concerned .i have had to replace some intake manifolds however it is important all clips and/or retainers are attached.dtc cleared and see if it returns before further diag. feel free to send me later messages

[ruggratt]

Originally Posted by lilvinny

the rear does control the rear.the actuator also acts as a sensor so if that rod is not connected to both lever and actuator it will trip the code for not seeing closed voltage.both banks are independent so really don't be too concerned .i have had to replace some intake manifolds however it is important all clips and/or retainers are attached.dtc cleared and see if it returns before further diag. feel free to send me later messages

Well the retainers are missing/rotted away, but the rods were still in the linkages. I took the rod out of the back linkage (bank 1?) and moved the linkage back and forth and it springs back into place. However when I did the same to the front it moves freely as if there was/is no spring. It will stay wherever you put it until you re-attach it to the actuator.

[rrclyoung]

I have a 98' windstar with a 3.8 and I just had this problem. I had codes 1537 and 1538 because vacuum to the selenoid (located behind and attached to the upper intake manifold) that controls the IMRCs was disconnected. Here is how mine works. When the engine is started both actuators pull in (get vacuum)and close the secondary air intakes. Around 1500 RPM the actuators loose vacuum and the secondary air intakes open. I used a vacuum gauge on mine and get around 20" of vacuum at each one. Remember, if one has a torn diaphram vacuum will look low at the good IMRC, I suggest pulling both vacuum lines and plugging one with a screw while you look at the other with a vacuum gauge, it should have vacuum below 1500 RPM. I lost one IMRC actuator for a torn diaphram about 2 years ago and it only set one code. The part was $220.00 from ford, I bought a new clip also for about $5.00....

[rrclyoung]

I forgot to fully answer your question....assuming the 1996 is the same as th 1998 3.8L, and that is assuming alot. the vacuum is common to both. Bank #1 is the bank containing cyls 1, 2 & 3 and is closest to the firewall, Bank #2 is the bank containing cyls 4, 5 & 6 and is closest to the radiator. To see the solenoid that controls the IMRCs you will most likely have to pull the cowling and look at it with a mirror, it is behind and attached to the upper intake manifold. It is controlled by the PCM.........

[ruggratt]

Ok I did a test today. I took off the back actuator rod and pushed the actuator rod in and held my finger over the vacuum hole and it held position until I moved my finger so I believe that one is good. However the front one was a different story, it would not hold vacuum so I assume that is the bad one. Someone told me that the front actuator is for bank one, not the rear, which is weird but makes sense since it is the bad one. If I take off the vacuum from the front bad actuator and block the vacuum line with my finger the rear actuator opens at high rpm like it is supposed to. So I guess this means that I need the front actuator. Thanks to everyone for responding.

[wiswind]

Try these folks for your replacement part....

http://www.trademotion.com/partlocat...?siteid=214072

This is the link for Millenium Ford's online parts department. They seem to have good prices....and will save you some serious money. The IMRC actuators are a dealer only part.