Codes: P0135, P0141, P0155, P0161, P0403 and P0443

Tiny
TYPE85
  • MEMBER
  • 2008 FORD EXPLORER
  • 4.0L
  • 6 CYL
  • 2WD
  • AUTOMATIC
  • 100,000 MILES
I have an issue with all the sensors on the same circuit: all four O2 sensor heaters, EGR and PCV, see picture for codes. I checked the fuse (#42) and it's okay.
I replaced all four o2 sensors and the EGR only to discover that they weren't the problem!
I recently pressure washed the engine, maybe a connector got wet and corroded?
Friday, April 24th, 2020 AT 9:44 PM

26 Replies

Tiny
JACOBANDNICKOLAS
  • MECHANIC
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Did this start after pressure washing? If so, check all connections for water. I looked up every code. I looked up each code and the P0141, 155, and 161 start with saying check for possible related causes to P0135. See picture 1.

Now interestingly, if you look at pic 2, it shows the possible causes of a P0135. Note the one I highlighted. This is where I think you need to start. I feel water is causing a short and setting all of the codes you have.

Do this and let me know what you find.

Joe
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Friday, April 24th, 2020 AT 10:10 PM
Tiny
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The codes did show up afterwards, but I don't think it happened right away.
I was thinking that one of the connectors got water in it, according to this picture could it be connector #C133?
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Friday, April 24th, 2020 AT 10:34 PM
Tiny
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And where is that connector? I can't see it on the drivers side of the engine.
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Friday, April 24th, 2020 AT 10:34 PM
Tiny
JACOBANDNICKOLAS
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Hi,

Bank 1 will be on the passenger side of the vehicle. I attached a picture of where sensor 1 will be located.

Let me know if this helps.

Joe
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Saturday, April 25th, 2020 AT 10:30 PM
Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
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I have seen this before. Please check the PCM connector and if okay the PCM is bad. What happens is the oxygen sensor heater driver goes out. Here is how you replace the PCM in the diagrams below:

Flash Electrically Erasable Programmable Read Only Memory (EEPROM)
Description
The EEPROM is contained in an integrated circuit internal to the powertrain control module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle, and is capable of being programmed or flashed repeatedly.
As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate DTCs P1635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for DTC P1639. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block is displayed on the scan tool.
When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the scan tool displays a message indicating the need to flash the PCM again to reset the VID block.
Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the scan tool manufacturer's instruction manual for details.
Programming the VID Block for a Replacement PCM
The VID block on a replacement PCM is blank and requires programming. There are 2 procedures available. The first is an automatic data transfer from the old PCM to the new PCM, and the second is manual data entry into the new PCM.
Automatic data transfer is carried out if the old PCM is capable of communicating. This is done by using a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can then be downloaded to the new PCM after it has been installed.
Carry out manual data entry if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible scan tool, select and carry out the module/parameter programming, referring to the scan tool manufacturer's instruction manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in DTCs P1635 and P1639. You may be instructed to contact the As-Built Data Center for the information needed to manually update the VID block with the scan tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and Lincoln Mercury technicians, contact your National Hotline or the Professional Technician Society (PTS) website for As-Built data listed under the Service Publications Index. Non-Ford technicians use the Motorcraft(R) website at www. Motorcraft. Com. From the Motorcraft(R) homepage, use the search function to find the Module Programming or As-Built Data.
For Ford and Lincoln Mercury technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle.
Making Changes to the VID Block
A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to Module Reprogramming on the scan tool.
Making Changes to the PCM Calibration
At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production, or the need to reset the VID block because it has reached its limit. Refer to Module Reprogramming on the scan tool.

Check out the diagrams (below). Please let us know what happens.
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Monday, April 27th, 2020 AT 11:09 AM
Tiny
TYPE85
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Would running a "tune" on the ECU/PCM cause this issue? I can reload the original stock tune if need me. I have a diablo "predator" tuner, I'm running the "87oct tow tune", a few more horse power, firmer shifts and the fan clutch engages at a lower temperature.
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Monday, April 27th, 2020 AT 6:29 PM
Tiny
JACOBANDNICKOLAS
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Anything is possible. I didn't realize you had made these changes. For test purposes, I would return it to OEM specs and see if that eliminates the issues. If it still doesn't, I feel Ken is correct in saying the PCM or PCM connector will need replaced.

Joe
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Monday, April 27th, 2020 AT 9:23 PM
Tiny
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I just reloaded the stock tune, cleared the codes and they came right back.
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Monday, April 27th, 2020 AT 9:28 PM
Tiny
KEN L
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Did all the codes come back or just some, if so which ones came back? Please check the connector at the PCM you may have water damage.
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Tuesday, April 28th, 2020 AT 11:18 AM
Tiny
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They all came back, I believe they're all powered by the same circuit. I'll check the connector.
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Tuesday, April 28th, 2020 AT 11:22 AM
Tiny
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If I need to replace the ECM, how do I know what version I have?
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Tuesday, April 28th, 2020 AT 4:47 PM
Tiny
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Also, connectors and pins look good on the ECM, no corrosion.
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Tuesday, April 28th, 2020 AT 4:47 PM
Tiny
KEN L
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When you remove the PCM it will have a version number on it. If you can upload a picture of it so we can see.
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Wednesday, April 29th, 2020 AT 9:46 AM
Tiny
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Pulled the ECM, looks like it's an "8L2A-BA".
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Wednesday, April 29th, 2020 AT 9:06 PM
Tiny
TYPE85
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More importantly, I think I found the root cause of the issue: in February, I had replaced the heater valve (before the check engine light came on) and had to disconnect the rear sensor on the throttle body. Today after removing the ECM, I noticed the insulation on the wiring was crumbled, there was a spot where all the wires were exposed. I'm sure they were touching and shorting out! The insulation must have fallen apart when I was replacing the heater valve and causing the issue with the ECM.
The question is, did this burnout the driver for the o2 heaters, EGR and PCV valves?
PS, I re-wrapped the bare wires, installed the ECM, the engine runs fine but after a few cycles of the ignition, the same codes came back.
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Wednesday, April 29th, 2020 AT 9:15 PM
Tiny
KEN L
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Yep, that will do it. I would check the rest of the wiring harness as well, if no other issues replace the PCM. When wires are shorted like that it will cause the PCM to go out. Let us know what happens.
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Thursday, April 30th, 2020 AT 10:14 AM
Tiny
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Is there any issue running the engine in this condition? O2 sensors are working, is the PCV valve working? If it isn't will it cause an issue?
Thanks
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Wednesday, May 6th, 2020 AT 3:49 PM
Tiny
KEN L
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Yes, it can cause issues such as melting the catalytic converter or the engine can stop running at anytime. You can get a rebuilt PCM for about $130.00.
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Thursday, May 7th, 2020 AT 10:28 AM
Tiny
TYPE85
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Any recommendations for rebuilt PCM's? I've only seen rebuilt ones for a round $600.00!
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Thursday, May 7th, 2020 AT 10:58 AM
Tiny
KEN L
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Here they are for $199.00:

https://circuitboardmedics.com/ford-pcm-repairs/

Let us know what happens please.
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Saturday, May 9th, 2020 AT 11:54 AM

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