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Old 01-07-2009, 06:22   #1 (permalink)
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96 Windstar Codes - Any Help Appreciated!

Hi to one and all,

Our 96 Winstar (ca. 122k miles) runs code P1537 and P1538 (stuck intake manifold runner control) when checked at Autozone. The car runs fine and because of its age (and our finances), we do not want to invest much more into it. It was turned down at inspection because the check engine light was on. It has been going off and on for years! We've had wiring re-done in the past at great expense, also tune-up. The light stays off a while and then comes back on. We are desperate to get it past inspection.

Here are my questions:

1. Autozone erased the codes and the light doesn't come on at the moment. Since the light is off, if I take it to inspection at this moment, will it pass?

2. Can anybody recommend what a non-mechanic like me might be able to do or try on a do it yourself basis?

2. If I absolutely have to to take it to a shop, what are the cheapest and most obvious things I could ask the mechanic to look at first?

3. I have heard that there can be a problem with clips or holders. Does anybody have any experience with these? Any tips?

I would be grateful for any and all feedback. We are facing tough times and need the van, so your ideas would be very welcome.

Thanks,
chelsea121
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Old 01-07-2009, 20:00   #2 (permalink)
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Re: 96 Windstar Codes - Any Help Appreciated!

Quote:
Originally Posted by chelsea121 View Post
Hi to one and all,

Our 96 Winstar (ca. 122k miles) runs code P1537 and P1538 (stuck intake manifold runner control) when checked at Autozone. The car runs fine and because of its age (and our finances), we do not want to invest much more into it. It was turned down at inspection because the check engine light was on. It has been going off and on for years! We've had wiring re-done in the past at great expense, also tune-up. The light stays off a while and then comes back on. We are desperate to get it past inspection.

Here are my questions:

1. Autozone erased the codes and the light doesn't come on at the moment. Since the light is off, if I take it to inspection at this moment, will it pass?

2. Can anybody recommend what a non-mechanic like me might be able to do or try on a do it yourself basis?

2. If I absolutely have to to take it to a shop, what are the cheapest and most obvious things I could ask the mechanic to look at first?

3. I have heard that there can be a problem with clips or holders. Does anybody have any experience with these? Any tips?

I would be grateful for any and all feedback. We are facing tough times and need the van, so your ideas would be very welcome.

Thanks,
chelsea121



Hello and good day to you Chelsea:

P1537 AND P1538 - Intake Manifold Runner Control Stuck Open.

You might want to look at the imcr valve. It is probably sticking from carbon build up? Use top engine cleaner and clean the air plenum.

Once you have done this clear the codes and go for a ride. About 30 miles should do it. If you have anymore codes it will come back up.

The IMRC valves are located-in the lower intake and occasionally they sick due to carbon deposits.
However you probably have broken clips at the linkages. The controls are either vacuum motor operated or electrical motor operated depending on year model. As you look at the bottom of the intake from the passenger side of the vehicle you will see the rods that actuate the valves.
The plastic bushings have probably broken and the rods have fallen off.
The rods are about the size of a coat hanger.
You will need 2 bushings per rod for a total of 4 bushings.
Buy 6 of them, they are small and have a tendency to disappear while installing.
Be sure the valves turn back and forth in the intake or it will break the new bushings immediately.

Please check out this link, with some photos:

Pictures of IMRC controls


Hope this help, and good luck with this....
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Old 04-03-2009, 20:19   #3 (permalink)
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Re: 96 Windstar Codes - Any Help Appreciated!

Excellent response and description! Even I could understand it!! Photo's make the all the difference! Got involved with the system on a 1988 Caprice, was similar with a dirty EGR valve and actuating rod.

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