2015 FPIU, high DTE, catalytic issues. | Ford Explorer Forums

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2015 FPIU, high DTE, catalytic issues.

ZippyTheDoggy

Member
Joined
September 25, 2023
Messages
17
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Location
Wisconsin
City, State
Wisconsin
Year, Model & Trim Level
2015 Police Explorer
Alrighty! Where do I even start? I've got a 2015 FPIU, generally runs good and doesn't have many problems. The biggest issue I've been having is since about a month or two post-ownership, I've had catalytic converter-style problems.
At one point I was up to about 8 DTC's that I'd have appear every now and then, some activating the MIL, but didn't have any severe and immediate issues (stalling, engine performance issues, etc.). I've got some pictures attached (attachment 1, 2, and 3) of these DTCs.
I replaced the vapor canister purge solenoid (attachment 4), and got rid of all but one of those DTCs, P0430, a Catalyst System Efficiency Less Than Threshold - Bank #2, which every now and then triggers my MIL to activate, which I normally just clear- again it's not an immediate issue and isn't causing any issues.

In some of my diagnostics of this issue, I've spotted some possibly concerning numbers. At one point, as seen in attachment 5, my HO2S12 (bank 1 sensor 2) is at .19V, while the HO2S22 is at .77V. Without any in-depth knowledge of anything surrounding the catalytic system, that severe of a difference between banks gained my attention and so it aligned with my idea that possibly my Bank 2 Sensor 2 is having issues and should be replaced; I've got a spare O2 sensor already but I'm considering getting another so I can replace both Bank 2 sensors to eliminate both of them as potential causes of this DTC.
However, after around an hour of driving around and pushing the vehicle up to higher RPMs, which has triggered the MIL in the past, as well as a higher engine load up-hill, which also has triggered the MIL in the past, I've got nothing. Attachment 6 shows the graph of my sensors after that hour or so of driving around trying to get my MIL indicator to light up so I'd know what the sensors were reading exactly at the moment that it activated.

Overall the game plan is replace both Bank 2 sensors, if that doesn't work, I'd be looking at replacing the whole bank 2 catalytic converter.
I'm looking for some general information on norms of O2 sensors for this vehicle (2015 FPIU, 3.7L), as well as possibly any ideas of further diagnostics to perform to either ensure that it's an O2 sensor that's bad, or even if there's some way to rule that out and figure out that all that's left to do is replace the catalytic converter itself.
I do have quite a few recordings of my PCM's data stream that I can look at from the past to see other information like fuel trim, I haven't combed through all that data yet but I can in the future if someone would like a look at that.

Bringing up fuel trim, however, I've had issues with my DTE calculations, where after filling my tank most recently, it says I can go 780mi till empty. I don't know if that has anything to do with the issues that could be going on, or if I've just got to reset my fuel trims every now and then or re-calibrate my DTE calculations. See attachment 7 and 8.

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I have had all those similar issues. First I was having codes for bad 02 sensors which I replaced 3 of the 4. A month later I got the 0420 code. In my state emissions are not required so I used an 02 sensor bypass adaptor on the downstream sensor of bank two and it has fixed the issue going on 4-5 months now. If the cats are plugged to the extent you notice performance issues then the only fix is replacing the cats. If you have to get emissions testing in your area then the only legal way to fix is by replacing the cats. I highly recommend going OEM and staying away from the cheaper aftermarkets as they will only last a year or two.

For the DTE I was getting 999 on fill up and 350 at empty. Something had gotten messed up in my IPC. If you have been playing around with Forscan and have a backup of your IPC try loading it and it should fix the issue. If you don't have a backup, make one with your current configuration and then use Forscan to download and load in the Factory as-built. This solved the issue for me.
 






P0420 and P0430 are bad cats for Bank 1 and 2
 






In my state emissions are not required so I used an 02 sensor bypass adaptor on the downstream sensor of bank two and it has fixed the issue going on 4-5 months now.
I don't have any state-mandated emission testing either, luckily. I've not noticed any performance issues at this point, but I did get sent a link for some O2 sensor spacers. Are these pretty much the same as the bypass adaptors you've mentioned?

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I don't have any state-mandated emission testing either, luckily. I've not noticed any performance issues at this point, but I did get sent a link for some O2 sensor spacers. Are these pretty much the same as the bypass adaptors you've mentioned?

View attachment 450371
Yes, Here is the exact ones I used which look a little different, but I imagine they work the same. Just remember they are only needed on the downstream sensors.
 






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