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Old 08-04-2012, 09:28 PM   #1
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2005 ST P2004 Help

Like it says in the title: 2005 ST 2.3L CEL with p2004 code.

Vacuum lines are not blocked.

There is also a loud clicking coming from the intake manifold. When I remove the left vacuum line from the manifold (top side just below the solenoid) the clicking stops. Maybe this is the tumble-flap sticking? I am unsure.

I need to know if the problem is the solenoid(s), the manifold itself, or other?

Any help is greatly appreciated!


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Old 08-04-2012, 09:56 PM   #2
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P2004 Intake manifold runner control stuck open
The fact the clicking stops when the vacuum is removed would indicate the tumbler flap mechanism itself (within the intake port) is making the clicking noise.
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Old 08-04-2012, 10:25 PM   #3
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P2004 Intake manifold runner control stuck open
The fact the clicking stops when the vacuum is removed would indicate the tumbler flap mechanism itself (within the intake port) is making the clicking noise.
That's what I am thinking. My next question would be why isn't the tumble flap working properly? The vacuum is good which leaves the solenoid not actuating, or the flap itself, unless there is something else?

I can eliminate the solenoid by swapping them to see if the problem follows. If it doesn't, I want to be sure there is nothing else before I go ripping into the intake. It is both expensive and a big job.
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Old 08-04-2012, 11:33 PM   #4
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http://www.focusfanatics.com/forum/showthread.php?t=281808
Post #6 has an interesting link with pictures. Rattling butterfly valves due to worn support bearings was the apparent noise cause.
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Old 08-05-2012, 12:05 AM   #5
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SOB and piss on me. I think I have my answer. Thanks a lot.
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Old 08-05-2012, 07:19 AM   #6
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I've got that problem too. Removing the tumble flaps causes a loss of low end torque, but the only way to replace them is to purchase a new intake manifold.
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Old 08-06-2012, 03:08 AM   #7
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I've got that problem too. Removing the tumble flaps causes a loss of low end torque, but the only way to replace them is to purchase a new intake manifold.
Yep, I saw your thread. I am working on getting a replacement intake manifold. I am not looking forward to the job to be honest, but I will be damned if I am paying some mechanic $500 in labor for turning a few bolts.
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Old 08-06-2012, 12:26 PM   #8
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One more question. When I disconnect the IMRC solenoid from the wiring harness, the rattling stops. Just to be sure, this means my solenoids are working, correct?
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