P2096 - '12 3.5 eco f150

DSG2003Mach1

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back story - bank 2 cat took a shit, probably due to getting the good old ecoboost shudder a couple times back in the day. Couldn't find an OE cat or even a date on when I could get one. I put SPD Performance catted downpipes on it. I replaced all 4 sensors while I was in there.

Only other mods are a CVF intercooler and tuned.

Ever since I've been getting that P2096 which is a bank 1 lean code, which appears to come from the cat monitor sensor, not the front wideband. If I'm cruising on the interstate I might go hours between lights but in town it's usually less than 20 miles.

Tuner's reply is basically you have aftermarket downpipes with aftermarket cats, get ****ed. Searching the web seems other people's tuners (post EPA BS) made tune adjustments and the light stopped. I know they aren't supposed to mess with anything that would effect the cat below threshold CEL from working but to me a lean code is a lean code and seems that bank needs more fuel (which, with a higher flow cat, doesn't seem too wild).

I will say I put nonfoulers on there to try and avoid a cat below threshold light, the little crush seals on them don't seem to be very good and did not evenly squish. I took the spacers out last night to see what happens. I made it to the store last night and work today without a light, see what happens from there.

If nothing else I'd just like to better understand why this is caused by an inefficient cat and isn't just a fueling issue
 

01yellercobra

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Could you have an exhaust leak? Didn't you mention there's an issue with the exhaust manifolds on those engines at some point?

If the non-fouler doesn't work maybe you can try the mini cats.

 

DSG2003Mach1

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Could you have an exhaust leak? Didn't you mention there's an issue with the exhaust manifolds on those engines at some point?

If the non-fouler doesn't work maybe you can try the mini cats.


I dont think I mentioned the manifolds but apparently people do have issues. I don't hear any sound that would go with a leaking manifold. I put the downpipes in on a Sunday, started throwing codes on my road trip Wednesday.

The only places for an exhaust leak are 1) downpipes to turbo and those got snugged with the big Milwaukee so unless theres a goofy spot in the flange (that wasn't a dent, I checked for cracks etc... before installing) 2) the o2 bungs themselves or 3) the non-foulers. All other joints are AFTER the sensors by a good 6" or more.

It’s my understanding this lean code is triggered off the rear sensor readings vs the front sensor readings, so ultimately the rear sensor is responsible.

The no foulers aren’t tall enough so you drill out one and stack it in another one. I’m wondering if either the excess height or the poor crush washer seal is causing the problem, that’s why I removed them last night and see what happens.

If this fixes my lean code and I end up with cat below threshold codes I’ll probably try the little mini cat things you linked to

Honestly, if the CEL didn’t prevent remote start from working I wouldn’t give a shit

Edit: made it to the store and back last night, work and home today with no code. Dunno if the lack of a light is after doing the KAM reset or if the non foulers were an issue. Trying not to get my hopes too high
 
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03cobra#694

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My 18 2.7 throws rear O2 (cats) CEL's constantly. I had replaced them way back, and it was good for 6 months. Came back, and just live with the light.
 

DSG2003Mach1

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My 18 2.7 throws rear O2 (cats) CEL's constantly. I had replaced them way back, and it was good for 6 months. Came back, and just live with the light.
Mine was going off constantly, mode 6 data showed the cat was bad and I was over the CEL all the time. I let the dog ride along frequently so I need remote start to work so I can leave her in the truck

Traded one problem for another it seems
 

DSG2003Mach1

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Probably. I'd love to find a perm cure for this.
They replace the cats or the sensors? Seems like a ton of people were replacing cats under warranty.

Take your fancy laptop and download forscan, but the $50 cable on Amazon and look at mode 6 data. It’ll tell you the oxygen capacity of the cats and if they’re outta spec
 

03cobra#694

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They replace the cats or the sensors? Seems like a ton of people were replacing cats under warranty.

Take your fancy laptop and download forscan, but the $50 cable on Amazon and look at mode 6 data. It’ll tell you the oxygen capacity of the cats and if they’re outta spec
I replaced the O2's myself. I have Forscan, never used it.
 

DSG2003Mach1

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I replaced the O2's myself. I have Forscan, never used it.
I don’t think you need the activation code (gotta renew it every two months or pay $12 for the year). Hook it up to the truck, hit the little connect button then I think it’s the wrench and can pick mode 6 and read the test results. Cat stuff is towards the bottom
 

DSG2003Mach1

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tuner did email back today - the front wide bands show that fueling is correct, it's responding as it should and fuel trims are in range. The fact that this code is solely based off the rear O2 sensor means there's an issue after the front sensor so it really isn't a tune issue and all they could do is have it not report that code which is now frowned upon by our lovely alphabet boys.

still not holding my breath but day 3 after removing the non-foulers and beat on the truck a bit today, so far so good.
 

hotcobra03

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I was just reading pinpoint test for 2096 who's 02 sensors did you use

P2096 - Post Catalyst Fuel Trim System Too Lean Bank 1


Description:
The PCM monitors the correction value from downstream heated oxygen sensor (HO2S) as part of the fore-aft oxygen sensor control routine. This DTC sets when the correction value is greater than a calibrated limit.​
Possible Causes:
  1. Corrosion
  2. Incorrect connections
  3. Exhaust leaks
  4. Contaminated universal heated oxygen sensor bank 1, sensor 1 (HO2S11)
Diagnostic Aids:
Inspect the connectors for signs of damage, water ingress, or corrosion.​
Application
Key On Engine OffKey On Engine RunningContinuous Memory
All​
GO to Pinpoint Test DZ.
 

hotcobra03

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YOUR CURRENT VEHICLE
2012 Ford F-150Change Vehicle
  • Repair
  • Maintenance
  • Labor Estimating
  • Bulletins/Recalls


Table of Contents



DZ: Universal Heated Oxygen Sensor (HO2S)
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2012 PCED Gasoline Engines​
SECTION 5: Pinpoint Tests​
Procedure revision date: 01/14/2014​

DZ: Universal Heated Oxygen Sensor (HO2S)​
← DZ: Introduction​

DZ1 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS)​

Are DTCs P0030, P0040, P0050, P0053, P0059, P0130, P0131, P0132, P0133, P0134, P0135, P0150, P0151, P0152, P0153, P0154, P0155, P1127, P164A, P164B, P2096, P2097, P2098, P2099, P2237, P2240, P2243, P2247, P2251, P2254, P2626, P2627, P2628, P2629, P2630, or P2631 present?
YesNo
For DTC P0040, GO to DZ6.
For DTC P1127, GO to DZ17.
For DTCs P0133, P0153, P2096, P2097, P2098 or P2099, GO to DZ18.
For DTCs P164A, P164B, P2626, P2627, P2628, P2629, P2630 or P2631, GO to DZ23.
For all others, GO to DZ2.​
For symptoms without DTCs, GO to DZ23.
For all others, GO to Section 4, Diagnostic Trouble Code (DTC) Charts and Descriptions.​

DZ2 VISUALLY INSPECT THE UO2S HARNESS​

  1. Ignition OFF.
  2. Visually inspect for:
    1. pinched, shorted, and corroded wiring and pins
    2. oil or water contamination
    3. crossed sensor wires
    4. damaged UO2S sensor
Is a concern present?
YesNo
REPAIR as necessary.
Clear the PCM DTCs. REPEAT the self-test.​
For DTCs P0030 or P0050, GO to DZ3.
For DTCs P0053, P0059, P0135 or P0155, GO to DZ7.
For DTCs P0130, P0131, P0132, P0150, P0151, P0152, P2243, P2247, P2251 or P2254, GO to DZ12.
For all others, GO to DZ16.​

DZ3 CHECK FOR MISFIRE CONCERNS AND AFTERMARKET EQUIPMENT​

  1. Ignition OFF.
  2. Check for the following:
    1. misfire concern
    2. non-factory or aftermarket equipment that may increase the exhaust temperature
  3. Universal HO2S-Front connector disconnected.
  4. Check the universal HO2S connector for damage or corrosion.
Is a concern present?
YesNo
REPAIR as necessary.
Clear the PCM DTCs. REPEAT the self-test.​
GO to DZ4.​

DZ4 CHECK THE UO2SHTR CIRCUIT FOR A SHORT TO VOLTAGE​

  1. PCM connector disconnected.
  2. Ignition ON, engine OFF.
  3. Measure the voltage between:
    ( + ) Universal HO2S-Front Connector, Harness Side( - )
    UO2SHTR​
    Ground​
Is any voltage present?
YesNo
REPAIR the short circuit. Clear the PCM DTCs. REPEAT the self-test.​
GO to DZ5.​

DZ5 CHECK THE UO2S, UO2SGREF, UO2SHTR CIRCUITS FOR AN OPEN​

  1. Ignition OFF.
  2. Measure the resistance between:
    ( + ) Universal HO2S-Front Connector, Harness Side( - ) PCM Connector, Harness Side
    UO2S​
    UO2S​
    UO2SGREF​
    UO2SGREF​
    UO2SHTR​
    UO2SHTR​
Are the resistances less than 5 ohms?
YesNo
GO to DZ7.​
REPAIR the open circuit. Clear the PCM DTCs. REPEAT the self-test.​

DZ6 CROSSED SENSOR WIRES​

  1. Ignition OFF.
  2. Check the vehicle repair history.
  3. Verify the connectors are connected to the correct engine bank.
Is a concern present?
YesNo
REPAIR as necessary.
Clear the PCM DTCs. REPEAT the self-test.​
Unable to duplicate or identify the concern at this time.
GO to Pinpoint Test Z.​

DZ7 CHECK FOR VPWR​

  1. Ignition OFF.
  2. Universal HO2S-Front connector disconnected.
  3. Ignition ON, engine OFF.
  4. Measure the voltage between:
    ( + ) Universal HO2S-Front Connector, Harness Side( - )
    VPWR​
    Ground​
Is the voltage greater than 10 V?
YesNo
GO to DZ8.​
REPAIR the open circuit. CHECK the fuses.
Clear the PCM DTCs. REPEAT the self-test.​

DZ8 CHECK THE UO2SHTR CIRCUIT FOR AN OPEN​

  1. Ignition OFF.
  2. Universal HO2S-Front connector disconnected.
  3. PCM connector disconnected.
  4. Measure the resistance between:
    ( + ) Universal HO2S-Front Connector, Harness Side( - ) PCM Connector, Harness Side
    UO2SHTR​
    UO2SHTR​
Is the resistance less than 5 ohms?
YesNo
GO to DZ9.​
REPAIR the open circuit. Clear the PCM DTCs. REPEAT the self-test.​

DZ9 CHECK THE UO2SHTR CIRCUIT FOR A SHORT​

  1. Measure the resistance between:
    ( + ) Universal HO2S-Front Connector, Harness Side( - ) Vehicle Battery
    UO2SHTR​
    Negative terminal​

  2. Measure the resistance between:
    ( + ) Universal HO2S-Front Connector, Harness Side( - ) Universal HO2S-Front Connector, Harness Side
    UO2SHTR​
    UO2S​
    UO2SHTR​
    UO2SGREF​
    UO2SHTR​
    UO2SPC​
    UO2SHTR​
    UO2SPCT​
    UO2SHTR​
    VPWR​
Are the resistances greater than 10K ohms?
YesNo
GO to DZ10.​
REPAIR the short circuit. Clear the PCM DTCs. REPEAT the self-test.​

DZ10 CHECK THE INTERNAL RESISTANCE OF THE UNIVERSAL HO2S HEATER​

  1. Measure the resistance between:
    ( + ) Universal HO2S-Front Connector, Component Side( - ) Universal HO2S-Front Connector, Component Side
    VPWR​
    UO2SHTR​
Is the resistance between 1.8 - 6 ohms?
YesNo
GO to DZ11.​
INSTALL a new Universal HO2S. REFER to the Workshop Manual Section 303-14, Electronic Engine Controls.
RESET the keep alive memory (KAM). REFER to Section 2, Resetting The Keep Alive Memory (KAM).
REPEAT the self-test.​

DZ11 CHECK THE UO2SHTR CIRCUIT FOR AN INTERNAL SHORT TO GROUND​

  1. Measure the resistance between:
    ( + ) Universal HO2S-Front Connector, Component Side( - )
    UO2SHTR​
    Ground​
Is the resistance greater than 10K ohms?
YesNo
For DTCs P0030 or P0050, GO to DZ12.
For all others, GO to DZ28.​
INSTALL a new Universal HO2S. REFER to the Workshop Manual Section 303-14, Electronic Engine Controls.
RESET the keep alive memory (KAM). REFER to Section 2, Resetting The Keep Alive Memory (KAM).
REPEAT the self-test.​

DZ12 CHECK THE UO2S AND UO2SGREF CIRCUITS FOR AN OPEN​

  1. Ignition OFF.
  2. Universal HO2S-Front connector disconnected.
  3. PCM connector disconnected.
  4. Measure the resistance between:
    ( + ) Universal HO2S-Front Connector, Harness Side( - ) PCM Connector, Harness Side
    UO2S​
    UO2S​
    UO2SGREF​
    UO2SGREF​
Are the resistances less than 5 ohms?
YesNo
GO to DZ13.​
REPAIR the open circuit. Clear the PCM DTCs. REPEAT the self-test.​

DZ13 CHECK THE UO2S, UO2SGREF, UO2SPC, AND UO2SPCT CIRCUITS FOR A SHORT TO GROUND​

  1. Measure the resistance between:
    ( + ) Universal HO2S-Front Connector, Harness Side( - )
    UO2S​
    Ground​
    UO2SGREF​
    Ground​
    UO2SPC​
    Ground​
    UO2SPCT​
    Ground​
Are the resistances greater than 10K ohms?
YesNo
GO to DZ14.​
REPAIR the short circuit. Clear the PCM DTCs. REPEAT the self-test.​

DZ14 CHECK THE UO2S, UO2SGREF, UO2SPC, AND UO2SPCT CIRCUITS FOR A SHORT TO VOLTAGE​

  1. Ignition ON, engine OFF.
  2. Measure the voltage between:
    ( + ) Universal HO2S-Front Connector, Harness Side( - )
    UO2S​
    Ground​
    UO2SGREF​
    Ground​
    UO2SPC​
    Ground​
    UO2SPCT​
    Ground​
Is any voltage present?
YesNo
REPAIR the short circuit. Clear the PCM DTCs. REPEAT the self-test.​
GO to DZ15.​

DZ15 CHECK THE UO2SGREF CIRCUIT FOR VOLTAGE​

  1. Ignition OFF.
  2. PCM connector connected.
  3. Ignition ON, engine OFF.
  4. Measure the voltage between:
    ( + ) Universal HO2S-Front Connector, Harness Side( - )
    UO2SGREF​
    Ground​
    VehicleVoltage
    F-150 5.0L, F-150 6.2L, Mustang 5.0L, Mustang 5.4L2 - 2.4
    E-Series 4.6L, E-Series 5.4L, Edge 2.0L, Expedition, Explorer 2.0L, F-150 3.5L, Flex, Focus, MKS, MKT, Navigator, Taurus2.4 - 2.6
    All others3.5 - 3.7

  5. Universal HO2S UO2SGREF Circuit Voltage
Is the voltage within specification?
YesNo
INSTALL a new Universal HO2S. REFER to the Workshop Manual Section 303-14, Electronic Engine Controls.
RESET the keep alive memory (KAM). REFER to Section 2, Resetting The Keep Alive Memory (KAM).
REPEAT the self-test.​
GO to DZ28.​

DZ16 CHECK THE UO2SPC CIRCUIT FOR AN OPEN​

  1. Ignition OFF.
  2. Universal HO2S-Front connector disconnected.
  3. PCM connector disconnected.
  4. Measure the resistance between:
    ( + ) Universal HO2S-Front Connector, Harness Side( - ) PCM Connector, Harness Side
    UO2SPC​
    UO2SPC​
Is the resistance less than 5 ohms?
YesNo
INSTALL a new Universal HO2S. REFER to the Workshop Manual Section 303-14, Electronic Engine Controls.
RESET the keep alive memory (KAM). REFER to Section 2, Resetting The Keep Alive Memory (KAM).​
REPAIR the open circuit. Clear the PCM DTCs. REPEAT the self-test.​

DZ17 EXHAUST TEMPERATURE OUT OF RANGE​


  1. NOTE
    Diagnose all other powertrain related DTCs first.

  2. Ignition ON, engine running.
  3. Engine at normal operating temperature.
  4. Access the PCM and monitor the HTR11 (MODE) and HTR21 (MODE) PIDs.
Are the PID states ON?
YesNo
CARRY OUT the KOER self-test.​
RUN the engine until the PID indicates ON.
CARRY OUT the KOER self-test.​

DZ18 CARRY OUT THE KOER SELF-TEST​

  1. Engine at normal operating temperature.
  2. Carry out the PCM KOER self-test.
Are any DTCs present other than P0133, P0153, P2096, P2097, P2098, or P2099?
YesNo
DISREGARD the current diagnostic trouble code (DTC) at this time. DIAGNOSE the next DTC. GO to Section 4, Diagnostic Trouble Code (DTC) Charts and Descriptions.​
For DTCs P0133 or P0153, GO to DZ21.
For all others, GO to DZ19.​

DZ19 VISUALLY INSPECT THE UPSTREAM AND DOWNSTREAM HO2S CONNECTORS​

  1. Ignition OFF.
  2. HO2S connector disconnected.
  3. Universal HO2S-Front connector disconnected.
  4. Check for a loose connection, and damaged or corroded terminals.
Is a concern present?
YesNo
REPAIR as necessary.
RESET the keep alive memory (KAM). REFER to Section 2, Resetting The Keep Alive Memory (KAM). REPEAT the self-test.​
GO to DZ20.​

DZ20 CHECK FOR LEAKS IN THE EXHAUST SYSTEM​

  1. Visually inspect the exhaust system for the following:
    1. exhaust leaks at flanges and gaskets
    2. HO2Ss not tightened to specification
    3. physical exhaust system concerns
    4. aftermarket exhaust
    5. punctures or cracks in the catalytic converter
Is a concern present?
YesNo
REPAIR as necessary.
RESET the keep alive memory (KAM). REFER to Section 2, Resetting The Keep Alive Memory (KAM). REPEAT the self-test.​
GO to DZ21.​

DZ21 CHECK FOR POTENTIAL SENSOR CONTAMINATION CONCERNS​

  1. Investigate the following items as potential sources of universal HO2S contamination:
    1. use of unapproved silicon sealers
    2. fuel contaminated by silicon additives
    3. excessive oil consumption
    4. glycol leaking internally in the engine
    5. lead-contaminated fuel
    6. short drive cycles in cold weather
    7. use of unapproved cleaning agents
Is a concern present?
YesNo
REPAIR the source of the contamination.
INSTALL a new Universal HO2S sensor. REFER to the Workshop Manual Section 303-14, Electronic Engine Controls.
CHANGE the engine oil and oil filter.
RESET the keep alive memory (KAM). REFER to Section 2, Resetting The Keep Alive Memory (KAM).
REPEAT the self-test.​
For DTCs P0133 or P0153, GO to DZ22.
For all others, INSTALL a new Universal HO2S sensor. REFER to the Workshop Manual Section 303-14, Electronic Engine Controls.
RESET the keep alive memory (KAM). REFER to Section 2, Resetting The Keep Alive Memory (KAM). REPEAT the self-test.​

DZ22 CHECK THE UNIVERSAL HO2S RESPONSE TEST RESULTS​

  1. Ignition ON, engine OFF.
  2. Access the diagnostic monitoring test results for the HO2S11 and HO2S21. Refer to Section 2, Diagnostic Monitoring Test Results Mode 6.
Is the indicated value greater than the minimum threshold?
YesNo
Unable to duplicate or identify the concern at this time.
Clear the PCM DTCs. REPEAT the self-test.​
INSTALL a new Universal HO2S. REFER to the Workshop Manual Section 303-14, Electronic Engine Controls.
RESET the keep alive memory (KAM). REFER to Section 2, Resetting The Keep Alive Memory (KAM).
REPEAT the self-test.​

DZ23 CHECK THE UO2SPCT CIRCUIT FOR AN OPEN CIRCUIT​

  1. Ignition OFF.
  2. Universal HO2S-Front connector disconnected.
  3. PCM connector disconnected.
  4. Measure the resistance between:
    ( + ) Universal HO2S-Front Connector, Harness Side( - ) PCM Connector, Harness Side
    UO2SPCT​
    UO2SPCT​
Is the resistance less than 5 ohms?
YesNo
For DTC P2626 or P2629, GO to DZ27.
For all others, GO to DZ24.​
REPAIR the open circuit. Clear the PCM DTCs. REPEAT the self-test.​

DZ24 CHECK THE UO2SPCT CIRCUIT FOR A SHORT TO GROUND​

  1. Measure the resistance between:
    ( + ) PCM Connector, Harness Side( - )
    UO2SPCT​
    Ground​
Is the resistance greater than 10K ohms?
YesNo
GO to DZ25.​
REPAIR the short circuit. Clear the PCM DTCs. REPEAT the self-test.​

DZ25 CHECK THE UO2SPCT CIRCUIT FOR A SHORT TO VOLTAGE​

  1. Ignition ON, engine OFF.
  2. Measure the voltage between:
    ( + ) Universal HO2S-Front Connector, Harness Side( - )
    UO2SPCT​
    Ground​
Is any voltage present?
YesNo
REPAIR the short circuit. Clear the PCM DTCs. REPEAT the self-test.​
GO to DZ26.​

DZ26 CHECK THE RESISTANCE OF THE LABEL RESISTOR IN THE UNIVERSAL HO2S​

  1. Measure the resistance between:
    ( + ) Universal HO2S-Front Connector, Component Side( - ) Universal HO2S-Front Connector, Component Side
    UO2SPCT​
    VPWR​
Is the resistance between 3.5K - 999.9K ohms?
YesNo
For DTCs P164A or P164B, unable to duplicate or identify the concern at this time.
GO to Pinpoint Test Z.
For DTCs P2627, P2628, P2630 or P2631, GO to DZ28.​
INSTALL a new Universal HO2S.
REFER to the Workshop Manual Section 303-14, Electronic Engine Controls.
RESET the keep alive memory (KAM), REFER to Section 2, Resetting The Keep Alive Memory (KAM).
REPEAT the self-test.​

DZ27 CHECK THE RESISTANCE OF THE CURRENT TRIM RESISTOR IN THE UNIVERSAL HO2S​

  1. Measure the resistance between:
    ( + ) Universal HO2S-Front Connector, Component Side( - ) Universal HO2S-Front Connector, Component Side
    UO2SPCT​
    UO2SPC​
Is the resistance between 25 - 330 ohms?
YesNo
For DTCs P2626 or P2629, GO to DZ28.
For all others, RETURN to Section 3, No Diagnostic Trouble Codes (DTCs) Present Symptom Chart Index for further direction.​
INSTALL a new Universal HO2S. REFER to the Workshop Manual Section 303-14, Electronic Engine Controls.
RESET the keep alive memory (KAM), REFER to Section 2, Resetting The Keep Alive Memory (KAM).
REPEAT the self-test.​

DZ28 CHECK FOR CORRECT PCM OPERATION​

  1. Disconnect all the PCM connectors.
  2. Visually inspect for:
    1. pushed out pins
    2. corrosion
  3. Connect all the PCM connectors and make sure they seat correctly.
  4. Carry out the PCM self-test.
  5. Verify the concern is still present.
Is the concern still present?
YesNo
INSTALL a new PCM. REFER to Section 2, Flash Electrically Erasable Programmable Read Only Memory (EEPROM), Programming the VID Block for a Replacement PCM.​
The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.​
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JaCobro

Luke 10:19
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In my experience, most of the time that code appears after cat replacement due to a leak. Which sometimes was very small and hardly noticeable. I think you are right with the anti-fouler maybe causing the issue.
 

DSG2003Mach1

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I used all motorcraft sensors from Rock Auto, so no amazon/ebay counterfeit BS.

I'll post a pic later of the doorman non-foulers. The crush washer seal they use doesn't fit well (too big), so one side gets crushed and the other doesn't, probably a better seal without it but will continue running with them off for a while and see what happens
 

JaCobro

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Should be able to do self test with forscan. Not sure about xcal.

Also you can check your catalyst IM/readiness monitors, if its ready you should be good to go.
 

DSG2003Mach1

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Should be able to do self test with forscan. Not sure about xcal.

Also you can check your catalyst IM/readiness monitors, if its ready you should be good to go.
definitely not with the Xcal.

ran the KOER test and no codes, nothing pending, no issues.
 

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