Code: P05A1-Active Grille Air Shutter 'A' Position Sensor Minimum/Maximum Stop Performance

[idanny76]

I ordered a new grille shutter and installed it. It's a 2016 Ford Explorer Limited. When I turned it on, it goes through the open and closing check. The shutter check takes a couple of minutes and then stays open. Then I check the engine codes again and it keeps showing the same Code: P05A1-Active Grille Air Shutter 'A' Position Sensor Minimum/Maximum Stop Performance. The shutters open and close properly and I don't see how the upper A section of the shutter is not opening or closing fully.

Is this a shutter issue or the actuator issue? I can video the shutters opening and closing without any issues. There's a slight resistance opening, but nothing severe. I'll post video here in a couple of minutes.

 

[idanny76]

I did receive the PCM code after that video. At the. End of the failed check.... The grille stays open, because it failed the test. Why would it keep failing the test if they do both close and open without any obstruction?

 

[FordFlintrock]

Looks to me the top set is fully closing while the lower do not by a small margin, would that be correct?

 

[idanny76]

Looks to me the top set is fully closing while the lower do not by a small margin, would that be correct?

Yes, but it's such a tiny gap. I don't even know how to adjust such a small gap. Is the actuator so sensitive that it would fault such a miniature gap? It reports the issue as to being the A section which is the top part. Going to try adjusting it somehow, but I don't know if the issue might be with the actuator.

 

[FordFlintrock]

I would presume the actuator is not traveling the full distance and the PCM is seeing that. Remove the one 7mm screw center bottom of shutters and slide the arm that goes to top shutters out of bracket. With the arm clear of bottom shutter movement re-test shutter. See if it will then close all the way and second if it still shows the code after clearing.

 

[idanny76]

I would presume the actuator is not traveling the full distance and the PCM is seeing that. Remove the one 7mm screw center bottom of shutters and slide the arm that goes to top shutters out of bracket. With the arm clear of bottom shutter movement re-test shutter. See if it will then close all the way and second if it still shows the code after clearing.

Here are two videos. One is the actuator bouncing back quickly during the closing phase. The other is the shutters better aligned. I am thinking is the actuator. I bought the explorer s couple of months back. The previous owner someone how managed to poke something through the bottom grille and broke the shutters. I just replaced the shutters only since the motor was still operational. But now thinking the force that broke the shutters might have misaligned the actuator?

 

[idanny76]

I would presume the actuator is not traveling the full distance and the PCM is seeing that. Remove the one 7mm screw center bottom of shutters and slide the arm that goes to top shutters out of bracket. With the arm clear of bottom shutter movement re-test shutter. See if it will then close all the way and second if it still shows the code after clearing.

Let me try that.... Disconnecting the top shutter from below and see if I still get the error code. I guessing that if the code still appears that the actuator was damaged by what ever broken the shutters with the previous owner.

 

[FordFlintrock]

Alignment of actuator prolly not. The upper and lower grill shutters are not in sync. Grill shutters on a scan tool have a value of 0 being closed and 100 fully open with yours likely not hitting the zero number.

 

[idanny76]

Alignment of actuator prolly not. The upper and lower grill shutters are not in sync. Grill shutters on a scan tool have a value of 0 being closed and 100 fully open with yours likely not hitting the zero number.

View attachment 453407

Still getting the error code. What do you think it is? Broken actuator? I bought the grille assembly, but It was missing the motor. I thought I might be able to do the shutter and get a refund for the missing actuator. I can have them send me a replacement with the actuator.

 

[FordFlintrock]

Do they close completely now? Disconnect actuator and cycle key a couple times to possibly clear any learned limits and try again after clearing codes. I do not see how the ambient temp sensor being disconnected could screw it up but plug that in and try again.
I would like to know the values on a scanner 1st before proceeding.

 

[idanny76]

Do they close completely now? Disconnect actuator and cycle key a couple times to possibly clear any learned limits and try again. I do not see how the ambient temp sensor being disconnected could screw it up but plug that in and try again.
I would like to know the values on a scanner 1st and cannot recommend parts.

I posted the video link and the bottom closes completely while the top is disconnected. The learned limits should have been erased by now, since I disconnected the battery yesterday when I replaced the spark plugs and had to relearn the idle and driving habits. I'll show a video of the forscan reading the values for the shutter. I'll cycle the ignition a couple of times before starting it and I'll leave the top shutter disconnect also.

 

[idanny76]

Do they close completely now? Disconnect actuator and cycle key a couple times to possibly clear any learned limits and try again after clearing codes. I do not see how the ambient temp sensor being disconnected could screw it up but plug that in and try again.
I would like to know the values on a scanner 1st before proceeding.

Here is the forscan grille command. I unplugged the actuator, connected the bumper, cycled the ignition 3 times, reconnect the actuator, left the top shutter disconnected and setup forscan. Video link below

 

[idanny76]

I was looking at the video and noticed the fault was there immediately for the End stop not found.

 

[FordFlintrock]

The actuator in many ways is very similar to an HVAC actuator. Some HD trucks I have worked on the HVAC, control actuators have a physical learned position that ratchet not computer memory when it hit the stops. Remove actuator and with key turned on let it spin to a new position then reinstall.

I was looking at the video and noticed the fault was there immediately for the End stop not found.

Does sound like the actuator faulty.

 

[idanny76]

The actuator in many ways is very similar to an HVAC actuator. Some HD trucks I have worked on the HVAC, control actuators have a physical learned position that ratchet not computer memory when it hit the stops. Remove actuator and with key turned on let it spin then reinstall.

Does sound like the actuator faulty.

I will try that tomorrow. I went ahead and ordered a replacement..... Hopefully this time it comes with the actuator. I will run that test anyways, but I have a feeling the actuator was damaged by whatever pierced through the grille and broke off the shutters. I mean it was all broken in pieces. I think he might have replaced the radiator too. Looks like someone was working in that area and didn't put things back where they belonged. Sadly I have to remove the shutter and put the bumper back on and remove it again when the part arrives.

I was thinking of removing it completely, since here in Florida never gets really cold. I liked the idea of the engine reaching operating temperature faster and having some arodynamic when on the highway.

 

[idanny76]

I got the replacement and this time it did come with the actuator motor. I installed it and it's working as it's supposed to. I didn't get any error codes or faults. I guess the motor was out of alignment from the impact of what ever broke the shutters. The explorer is now up to date with the maintenance and repairs. My next project is to install running boards to make it easier getting in and out... Specifically for the 3 row seats. Thank you FordFlintrock for helping me out... Really appreciate it.

 

[FordFlintrock]

My pleasure. I hope to call Valrico home down there one of these days when done with the Docs.