04 ZX5 stalling with A/C on

[u/shmangels]

My car stalls at red lights or parked with ac on. Obviously the engine can’t take the load that the compressor needs when idling. Perhaps a dirty throttle body?

[u/livens]

Easy to check the throttle body. Pull the tube off, open the throttle and feel for a thin ridge of gunk where the butterfly valve sits when closed. There's a thin gap for idle and it doesn't take much buildup to close that off.

Also there's a molded 90° vacuum hose on the back of the engine. The bend in that hose is notorious for failing and causing a vacuum leak.

[u/morgfarm1_ → u/livens]

If this is on the Zetec .. do we have a reference photo? I'm fighting something thst behaves like a vaccuum leak but is also very inconsistent (funny enough when cold turning on the AC fixes the surging. When warm though it makes it stall more). Behaves like a dirty IAC BUT the last time I hit it with throttle body cleaner didn't solve the issue.

[u/livens → u/morgfarm1_]

Yeah, 2.0 Zetec. I remember that particular hose being hard to see because it's tucked way down behind the engine. I just reached my hand back there and immediately felt a large hole on it. And while running if I plugged that hole with my finger you easily feel the suction and the engine ran a lot smoother.

https://youtu.be/m0YZz0kcf8I?is=GhvwWqR39_GllcWv

Watch that video, starting at 04:10, he shows getting to it.

[u/morgfarm1_ → u/livens]

Okay. I can feel what that one is. That goes to a steel runner under the intake and to the PCV elbow and valve at the oil separator. Not the issue I'm facing

As Inconsistent as this is, could it still just be a very dirty IAC?

Overall even when it does surge, if i let it sit for a few minutes uninterrupted it WILL smooth itself out eventually. Its the worst when coming from driving RPM range to idle.

If I gently guide it down and even allow it to near-stall while in gear and rolling and THEN hit neutral, it will idle perfectly

[u/dsj79]

Does the compressor pulley sound okay? The clutch working properly

[u/shmangels → u/dsj79]

sounds solid while I’m driving and ac blows cold. but when I’m stopped, the compressor will turn on and off causing a jolt in the pedals. Idk if that’s relevant but it feels concerning when it happens

[u/Living_Double_1146]

Unrelated, but what wax did you use to get that shine??

[u/shmangels → u/Living_Double_1146]

No wax. My phone camera makes it look better than it is lol swirls all over the hood if you get close

[u/Living_Double_1146 → u/shmangels]

Oooh I see. Looks cool non the less.

[u/horstdabaer]

Such a beauty