Fix P2004: Mechanic’s solutions that WORKED

The code P2004: Intake Manifold Runner Control Stuck Open indicates a fault within the Intake Manifold Runner Control system, pinpointing that the control is stuck in the open position. This issue is most often due to mechanical failures within the intake manifold or an actuator malfunction, and less commonly related to electrical or vacuum problems.

P2004 quick overview

Meaning	P2004: Intake Manifold Runner Control Stuck Open
Is it serious?	It can lead to decreased engine performance, increased emissions, and in some cases, can cause the vehicle to fail an emissions test.
Possible causes	– Faulty intake manifold runner control actuator – Broken actuator mounting tabs – Obstructed or sticking intake manifold runners – Vacuum leaks affecting the intake manifold runner control system – Wiring or electrical connector issues
How to diagnose?	Visual Inspection: Check for any physical damage to the actuator and linkage. Scan Tool Testing: Utilize a scan tool to command the actuator and observe operation. Verify Vacuum Lines: Ensure that vacuum lines are connected properly and are in good condition. Check for TSBs: Look up any relevant technical service bulletins for guidance. Electrical Testing: Perform electrical tests to rule out wiring problems. OEM Parts: If replacement is needed, use OEM parts for reliability.

Think of the intake manifold runner control like a set of doors within your engine that open and close to control airflow. The code P2004 means these “doors” aren’t moving as they should be—they’re stuck open. This could make your engine run less smoothly and could potentially lead to other issues if not fixed. It’s like having a window in your house that won’t close; it’s not immediately dangerous, but it’s something you’ll want to fix to avoid problems like bad weather—or in your car’s case, poor performance.

How to fix P2004 – learn from mechanics

I looked into P2004 service cases at iatn.com website where in the private forums the mechanics seek advice from other mechanics. I looked up a bunch of cases to help you decide how to fix your issue and see what would a real mechanic do to solve it.

Case #1: Chrysler

Vehicle Information 2007 Chrysler Sebring 2.4L

Issue + Repair History

• MIL (Malfunction Indicator Lamp) on
• Codes: P2004 (Intake Runner Control Stuck Open)
• Previous unrelated repair: Front and Rear Brakes

Other OBD2 Codes + Test Results

• Not applicable/mentioned.

What are people suggesting to fix the issue

• Check for poor design and carbon build-up causing the intake runner to stick.
• Verify the function of the solenoid that opens/closes the intake runner.
• Attempt to manually move the intake runner to see if it’s stuck.
• Follow the TSB (Technical Service Bulletin) instructions to flash/update the PCM (Powertrain Control Module) and check or replace the actuator and intake manifold.
• In cases of additional codes and symptoms, check for leaks affecting sensors like the crank sensor.

What was the final fix: Replaced Intake Runner Control.

Case #2: Ford

Vehicle Information 2003 Ford Ranger XL 2.3L

Issue + Repair History

• MIL (Malfunction Indicator Lamp) on
• Code: P2004 (Intake Manifold Runner Control Stuck Open)
• Vehicle runs well, normal scan data stream

Other OBD2 Codes + Test Results

• Not applicable/mentioned.

What are people suggesting to fix the issue

• Follow the diagnostic chart (HU15) for guidance on intake manifold runner issues.
• Consult the Ford PC/ED for a description of code P2004 and its possible causes.
• Look for similar codes like P1518 and P1537 for diagnostic direction.
• Consider TSBs and additional resources for more information.

What was the final fix

• Found a plastic ball blocking the vacuum line from the IMRC actuator to the monitor.
• Replaced the vacuum line and retested all components.
• After several drive cycles, no codes pending, issue seems to be fixed.

Case #3: Kia

Vehicle Information 2011 Kia Forte EX 2.0L

Issue + Repair History

• MIL (Malfunction Indicator Lamp) on with a hard fault for the intake runner.
• Fault code immediately returns after being cleared.
• The intake valve can be commanded to open and close with a scan tool.

Computer Codes & Descriptions

• P2004: Intake runner performance Bank 1

What are people suggesting to fix the issue

• Check the actuator and the runner shaft for physical damage.
• It is common for the end of the runner shaft to break, leading to actuator failure.
• The consensus is that the manifold is likely broken and needs replacement.
• Advised against using aftermarket parts like those from Dorman due to poor experiences.

What was the final fix

• The ears were broken off the actuator.
• A used intake from a salvage yard was installed, which fixed the problem.

Case #4: Mercedes

Vehicle Information: 2008 Mercedes-Benz C300 Sport 3.0L

Issue + Repair History:

• MIL (Malfunction Indicator Lamp) on after intake flap repair.
• Concern about incorrect vacuum line connections post-repair.
• No helpful information from AllData.

Computer Codes & Descriptions:

• P0013: Exhaust camshaft actuator issue.
• P2004: Charge Movement Flap (Intake Manifold Runner) Bank 1 malfunction.

Resolution Steps:

• The owner sought help for a vacuum diagram for the intake manifold.
• Mechanic suggested checking the connector at the back of the manifold to ensure it’s plugged into the flap sensor.

Final Fix:

• The problem was resolved by referring to a YouTube video.
• Two vacuum lines were found to be crossed and were corrected accordingly.

Case #5: Jeep

Vehicle Information: 2009 Jeep Compass Sport 2.4L

Issue: MIL (Malfunction Indicator Lamp) on with codes P2017 and P2004 related to the intake manifold runner control.

Diagnostic Trouble Codes (DTCs) & Descriptions:

• P2017: Intake Manifold Runner Position Sensor/Switch Circuit High Bank 1
• P2004: Intake Manifold Runner Control Stuck Open

Community Suggestions for Diagnosis and Repair:

1. Perform a scan tool check for bi-directional control capability and listen for the actuator movement to diagnose the issue.
2. Refer to a TSB for potential replacement of the intake and reprogramming of the PCM.
3. Investigate the DTCs for potential issues with the wiring, actuator, physically stuck runner valve, or PCM fault.
4. Physically inspect the actuator and the gates in the intake manifold to see if they are stuck or able to be moved manually.
5. Conduct circuit tests between the actuator and PCM to rule out electrical problems as the root cause.
6. Check if there’s a known issue covered by a TSB, which may involve both replacing the intake manifold and updating the PCM software.
7. Replace the intake manifold if diagnostics indicate that the issue is mechanical within the manifold itself, such as a binding shaft that impedes the actuator’s function.
8. Ensure all other potential causes, such as electrical connections and the functionality of related components, are ruled out before proceeding with manifold replacement.

Resolution: The fix involved replacing the intake manifold, and it was noted that the job was not particularly difficult. After the repair, the vehicle was reported to have been running without the codes returning for at least two weeks.

Advice	Brief Description of Diagnostic Step
Check for physical damage	Inspect the intake manifold runner control actuator and shaft for any physical signs of damage or breakage, such as ears broken off the actuator or a broken runner shaft.
Perform actuator tests with a scan tool	Use a scan tool with bidirectional control capability to command the intake manifold runner valve open and closed to check for proper operation.
Inspect and verify vacuum lines and connections	Ensure that all vacuum lines are correctly connected and not crossed, particularly after repairs or maintenance that involves disconnecting them.
Consult manufacturer’s TSBs	Check for Technical Service Bulletins (TSBs) that might provide information on common issues and prescribed fixes, which may include part replacements or software updates.
Consider replacing the intake manifold if necessary	If diagnostics suggest a mechanical fault within the manifold or if actuator movement does not result in corresponding runner movement, replacement of the intake manifold may be required.
Rule out wiring and electrical issues	Before replacing parts, conduct thorough checks on the wiring and electrical connections to rule out these as the source of the problem.
Avoid aftermarket parts if quality is uncertain	When replacing parts, use OEM or reliable aftermarket parts to ensure proper function and avoid further complications, as some technicians have noted issues with certain aftermarket parts.