02 windstar how to repair/replace imrc

[Oldmanlat]

Hi.
I have a 2002 Windstar 3.8. I have all the symptoms of a stuck open IMRC.
Do you have instructions/photos to repair/replace these. I hear they're quite expensive. Could it be a vacuum leak, or rod bushings?
Also, how can I determine which bank, left or right is the problem side?
Any help would be appreciated,
Thanks in advance.
Oldmanlat NJ

[Oldmanlat]

Hi. It's me again.
The 2002 Windstar 3.8 DEFINITLY has only one IMRC.
It measures 3"W x 3"L x 3"H. It's located just to the right of the serpentine belt on the side of the engine block. It's connected to both the L & R banks of the intake manifold with (2) seperate linkage levers. There are (4) plastic bushings, one on each end of the 2 levers. The IMRC doesn't have any vacuum connections. It has one electrical connection on the top. On my 02 3.8, all 4 plastic bushings were cracked and the levers were disconnected from the intake manifold. I'm replacing the bushings along with the original IMRC. It wasn't that hard to get to. I hope I don't really need the IRMC !!
I paid $8.65 ea for the 4 plastic bushings. Ford p/n F5RZ9F955AB
The IMRC priced out at $222.60 Ford p/n XF229J559AA
(thank God there is only one)
See the photos of the IMRC already removed.
I hope this will help clear up some questions.
Later,
Oldmanlat NJ

engine side view
IMRC engine side view 2002 Windstar.jpg

top view
IMRC top view 2002 Windstar.jpg

[speralta]

Hi,
I have an '01 Windstar and have lost (due to worn out bushings, I'm sure) one of the linkages.
When you purchased the new IRMC, did it come with new linkages? Or do you have any idea where I might be able to find them? The dealer tells me that they don't show them as something they can get. They say I probably have to buy the whole lower manifold (which would come with the controller). I just need the linkages and bushings.
Thanks!

[Flyingjackal456]

hey should stock the linkages, maybe you should find the manager and ask him if why his dealer doesn't stock ford parts.

[speralta]

The parts guy at the counter showed me the exploded view of the manifold assembly when he was trying to find them. They simply were not shown either in the drawing or in the list of parts.
Should I try another dealer, or do you know of somewhere online that might be able to get them?

[Flyingjackal456]

I am surprised, you can try calling a few dealers... I am sad to say that the new design (1999+) use electric IMRC valves instead of vacuum operated... the newer design is almost impossible to find online....

Personally I am surprised that the dealer cannot find them, they usually have EVERYTHING. Although beware of high prices...

I went there looking for battery cables earlier this week, the guy printed out the invoice and asked me "Are you sure you even want to look at this?" (I'm standing there crapping my pants in suspense.) He said the list price is $500 dollars for the neg. and pos. cables.... I asked him why is my van only worth $3000? Luckily for me I didn't need the cables even though I found the Motorcraft parts online for $200.

I recommend using froogle.com (google shopping search engine) or visit/call a few junkyards. That would be your best bet.

[fordgaragemech]

I have both a 1996 Windstar 3.8 and a 1997 F-150 4.2. They both have the IMRC setup. Very cool design! At any rate, these runners (inside the intake) can get clogged up with intake gunk. Ford says you can and should use injector cleaner spray to keep these things operating freely. You simply need to remove the upper intake manifold and spray them out. On the F-150 the vacuum pots are at the back of the engine (pain!). There are little black, snap in bushings that connect the actuator rod of the pots to the IMRC rod. Ford says that you should replace these bushings if you ever need to disconnect them. I personally have reused them if they don't break. The part is available from Ford for about $8.00. Dorman also makes the part for cheaper (rockatuto.com) Part# 47099 about $4.00/ea (they're called IMRC Bushings)

At any rate, when vacuum is applied to the pot it closes the IMRC butterflys. If vacuum is off or inoperative the IMRC will remain open. For most around town driving the IMRC is closed. The IMRC opens at about 3500RPMs.

Quoted:

The IMRC system has two intake manifold runners per cylinder for air flow into the combustion chamber. One runner is always open and the other is commanded open by the Powertrain Control Module (PCM). Below approximately 3000 rpm, the valve plates are closed and above approximately 3600 rpm, the valve plates are opened. The PCM also receives a signal from the IMRC system indicating valve plate position. The quantity of air metered to the engine is controlled by the throttle body assembly.

The IMRC system also has a housing and actuator assemblies. The IMRC housing assembly is an aluminum casting with two air intake passages for each cylinder. One passage is always open and the other is opened or closed with a butterfly valve plate. The IMRC Actuator is either a remote mounted electro-mechanical control actuator or a direct mounted vacuum actuator type system. In the remote system, the IMRC housing valve plates are held closed with a return spring located on the valve plate shaft. When commanded open by the PCM, the IMRC actuator pulls on the IMRC shaft assembly using an accelerator type cable. On the direct mounted vacuum actuator system, the return springs are located within the vacuum actuator. The PCM commands a vacuum control solenoid allowing the vacuum to pass to the vacuum actuator drawing the valve plates closed or releasing the vacuum allowing the actuator to push the valve plates open. Substantial opening and closing torque is applied in both systems. Care should be taken to keep fingers away from the lever mechanisms when actuated. It also provides a switch signal to the PCM for the plate position.

End Quoted

Regardless, I have never had the actuators fail. Probably because I kept the butterflys clean by blasting them off with spray once every year or so. I simply remove the upper intake and get in there. Not too big a job at all. But that way the butterflys move freely and don't put undue strain on the actuator's diaphragm.

Hope this helps.

[Robmdall]

For the past week I have had my wife’s 2000 Windstar wire-tied about 1/2 open on both banks. All 4 bushings have turned to dust.

Prior to placing both in a fixed position the van ran ok while driving, but very poor while idling.

Since my 3 minute fix, all seems better, the van runs better than it has in ages, both highway and city.

My question is will I do any harm by leaving these valves in a fixed position?

Honestly, I don’t have a problem replacing the IMRC if it is bad. Is there a way to check it besides revving the engine and watching the arm to move?

Bob

[cjones]

aftermarket makes delete plates for the 4.6L engine so the engines breath better at higher rpms. you may want to check if they make them for your engine.

[Robmdall]

Delete Plates might be a bit extreme for the Windstar

The van is still running good, even appears to be getting better mileage (So says the wife).

I have looked through my repair manual and did a few Google searches for a test method of the system - no luck. Is the module simply a 12v motor.

Can someone point me in the correct direction. I hate to spend $200+ replacing the unit.

Thanks in advance for any replies.

Bob