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Intake manifold leak

Tiny
ONEMOBILEONE
  • MEMBER
  • 2005 FORD FOCUS
  • 2.0L
  • 4 CYL
  • FWD
  • AUTOMATIC
  • 133,000 MILES
I have change intake gasket, multiple vacuum lines, even those that did not appear cracked or broken. I have also changed out the intake idle control valve, map sensor signal was stuck at 1.35 volts on the return wire, a solid 5 volts on the supply side, new idle air control motor, cleaned throttle body. It still will stall on a hot engine restart (running temperature) and give me a dtc code of P2004.
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Friday, August 12th, 2016 AT 4:22 PM

9 Replies

Tiny
SATURNTECH9
  • MECHANIC
  • 30,870 POSTS
I see the number one fix is intake runner control solenoid valve.
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Friday, August 12th, 2016 AT 8:05 PM
Tiny
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  • 5 POSTS
Maybe, but that did not fix it.
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Saturday, August 13th, 2016 AT 8:44 AM
Tiny
ONEMOBILEONE
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I thought I had nailed it when I tested the map sensor and it failed, then removed it and it was full of gunk. So I changed it out tested it all good the car got to running temperature then I turned off the engine went to restart and it started and stalled and then started. At that point is when the hard code reappeared.
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Saturday, August 13th, 2016 AT 9:00 AM
Tiny
SATURNTECH9
  • MECHANIC
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Have you checked for blocked or lined vacuum lines to the solenoid?
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Sunday, August 14th, 2016 AT 4:23 PM
Tiny
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Blocked or kinked I mean?
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Sunday, August 14th, 2016 AT 4:24 PM
Tiny
ONEMOBILEONE
  • MEMBER
  • 5 POSTS
I have replaced all vacuum lines with new vacuum lines none are kinked
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Wednesday, August 17th, 2016 AT 12:35 PM
Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 42,940 POSTS
Can you remove the actuator and see if the can move the flap shaft by hand? Maybe it is stuck

Best, Ken
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Thursday, August 18th, 2016 AT 11:54 AM
Tiny
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  • 5 POSTS
Thanks Ken. When I changed the manifold gasket I painstakingly clean each ports butterfly valve to make sure everything was moving freely also checked the vacuum actuator. Applied vacuum to it and it also moved freely.
At this point I'm looking at the pcv valve it seems week to me. I would just pinch off the hose to it to test it but there's just not enough room behind the manifold to leave a clamp on it. I hate throwing parts at a car with out testing it. It's not the way I was taught. Have you ever had a pcv valve throw a code 2004?
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Friday, August 19th, 2016 AT 12:18 PM
Tiny
SATURNTECH9
  • MECHANIC
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If it was leaking vacuum it could.
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Friday, August 19th, 2016 AT 8:12 PM

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