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Lincoln Aviator 2020-2026 Service Manual / Powertrain / Exhaust System / Exhaust System - 3.0L EcoBoost / Diagnosis and Testing - Exhaust System

Lincoln Aviator: Exhaust System - 3.0L EcoBoost / Diagnosis and Testing - Exhaust System

Diagnostic Trouble Code (DTC) Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).


  Diagnostic Trouble Code Chart


Module   DTC Description Action
  PCM P0544:00 Exhaust Gas Temperature Sensor Circuit (Bank 1 Sensor 1): No Sub Type Information   GO to Pinpoint Test RB
  PCM P0545:00 Exhaust Gas Temperature Sensor Circuit Low (Bank 1 Sensor 1): No Sub Type Information   GO to Pinpoint Test RB
  PCM P0546:00 Exhaust Gas Temperature Sensor Circuit High (Bank 1 Sensor 1): No Sub Type Information   GO to Pinpoint Test RB
  PCM P0547:00 Exhaust Gas Temperature Sensor Circuit (Bank 2 Sensor 1): No Sub Type Information   GO to Pinpoint Test RB
  PCM P0548:00 Exhaust Gas Temperature Sensor Circuit Low (Bank 2 Sensor 1): No Sub Type Information   GO to Pinpoint Test RB
  PCM P0549:00 Exhaust Gas Temperature Sensor Circuit High (Bank 2 Sensor 1): No Sub Type Information   GO to Pinpoint Test RB

Global Customer Symptom Code (GCSC) Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).


  Global Customer Symptom Code Chart


Customer Symptom Action
Fit/Finish/Body > Paint/Finish > Exhaust > Corrosion/Rust   GO to Pinpoint Test C
Start/Run/Move > Noise > Exhaust > Always   GO to Pinpoint Test D
Driving Performance > Lack/Loss of Power > Acceleration > Always   GO to Pinpoint Test A
Safe & Secure > Smoke/Odor > Exhaust > Hot   GO to Pinpoint Test B
Runs Rough > Hesitates/Stumble > Acceleration   GO to Pinpoint Test RB

Symptom Chart(s)

Symptom Chart - Exhaust System

NOTE: Aftertreatment components consist of some or all of the following components: Catalytic Converters, Gasoline Particulate Filters, Diesel Particulate Filters, Selective Catalytic Reduction Catalysts, Exhaust Gas Heat Exchanger.

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).


  Symptom Chart


Condition Actions
Lack of power - vehicle performance complaint
  • GO to Pinpoint Test A
Odour from vehicle - possible sign of smoke
  • GO to Pinpoint Test B
Surface rust or degradation of surface treatment
  • GO to Pinpoint Test C
Noise such as buzzing, drumming, thumping, ringing or hissing coming from exhaust system
  • GO to Pinpoint Test D

Pinpoint Tests


PINPOINT TEST A : LACK OF POWER

NOTE: Aftertreatment components consist of some or all of the following: Catalytic Converters, Gasoline Particulate Filters, Diesel Particulate Filters, Selective Catalytic Reduction Catalysts.

Normal Operation and Fault Conditions

REFER to: Exhaust System - Overview (309-00A Exhaust System - 3.0L EcoBoost, Description and Operation).

Possible Sources

  • Exhaust pipe pinched or crushed
  • Damaged aftertreatment components
  • Loose obstruction in exhaust
  • Restricted exhaust (possible frozen condensate in mufflers or exhaust actuator valves)

Visual Inspection and Pre-checks

  • Inspect for loose, damaged, contaminated or incorrect components.
A1 CHECK THE EXHAUST SYSTEM FOR SIGNS OF DAMAGE
  • Inspect the exhausts system aftertreatment components and associated sensors for damage.

Is damage to the aftertreatment components and associated sensors found?
Yes INSTALL new components as necessary.
No GO to A2

A2 CHECK THE EXHAUST SYSTEM FOR OBSTRUCTIONS OR RESTRICTED FLOW
  • Inspect the exhausts system pipework for pinched or crushed components.

Is any flow restricting damage to the exhaust components seen?
Yes INSTALL new components as necessary.
No The condition may be intermittent. Advise the customer no repair is required.

PINPOINT TEST B : ODOUR FROM VEHICLE

NOTE: Aftertreatment components consist of some or all of the following: Catalytic Converters, Gasoline Particulate Filters, Diesel Particulate Filters, Selective Catalytic Reduction Catalysts.

Normal Operation and Fault Conditions

REFER to: Exhaust System - Overview (309-00A Exhaust System - 3.0L EcoBoost, Description and Operation).

Possible Sources

  • Damaged or contaminated aftertreatment components
  • Incorrect fuel or fuel with excessive sulfur content in fuel
  • Rich fuel conditions
  • Misfire conditions

Visual Inspection and Pre-checks

  • Inspect for loose, damaged, contaminated or incorrect components.
B1 CHECK FOR DAMAGED AFTERTREATMENT COMPONENTS ASSOCIATED SENSORS
  • Inspect the aftertreatment components and associated components for damage.

Have the aftertreatment components or associated electronic sensors incurred damage?
Yes INSTALL a new aftertreatment components as necessary.
No GO to B2

B2 CHECK FOR INCORRECT FUEL OR FUEL WITH A HIGH SULFUR CONTENT
  • Check the residual fuel in the fuel tank for incorrect fuel or fuel that contains a high sulfur content.

Does the fuel tank contain incorrect fuel or fuel high in sulfur content?
Yes Drain the fuel tank and flush the fuel system. Refill the fuel system with fuel containing the correct level of sulfur.
No GO to B3

B3 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION
  • Using a diagnostic scan tool, perform the PCM self-test.

Are the powertrain controls operating correctly?
Yes The condition may be intermittent. Advise the customer no repair is required.
No Correct and fix any powertrain control issues. Using a diagnostic scan tool, perform the PCM self-test. Test and confirm the issue has been resolved.

PINPOINT TEST C : SURFACE RUST OR DEGRADATION OF SURFACE TREATMENT

NOTE: Surface rust is a characteristic of materials used on exhaust systems. Exposure to heat or road salt may result in surface rust.

Normal Operation and Fault Conditions

REFER to: Exhaust System - Overview (309-00A Exhaust System - 3.0L EcoBoost, Description and Operation).

Possible Sources

  • Perforated catalytic converter/exhaust system

Visual Inspection and Pre-checks

  • Inspect for loose, damaged, contaminated or incorrect components.
C1 CHECK THE EXHAUST SYSTEM FOR PERFORATIONS, RUST OR DAMAGE
  • Visually inspect the exhaust system, paying specific attention to joints, bends, low points and check for rust, perforations or surface degradation.

Are perforations, rust or damage present?
Yes INSTALL new components as necessary.
No GO to C2

C2 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION
  • Using a diagnostic scan tool, perform the PCM self-test.

Are the powertrain controls operating correctly?
Yes The condition may be intermittent. Advise the customer no repair is required.
No Correct and fix any powertrain control issues. Using a diagnostic scan tool, perform the PCM self-test. Test and confirm the issue has been resolved.

PINPOINT TEST D : NOISE FROM EXHAUST SYSTEM

NOTE: Aftertreatment components consist of some or all of the following: Catalytic Converters, Gasoline Particulate Filters, Diesel Particulate Filters, Selective Catalytic Reduction Catalysts.

Normal Operation and Fault Conditions

REFER to: Exhaust System - Overview (309-00A Exhaust System - 3.0L EcoBoost, Description and Operation).

Possible Sources

  • Loose or damaged heat shield(s)
  • Loose or damaged exhaust isolators(s)
  • Damaged exhaust isolator hanger bracket
  • Loose or damaged aftertreatment components or mufflers
  • Exhaust system leak
  • Catalytic converter/exhaust system
  • Exhaust system grounded to chassis
  • Damaged or worn exhaust system
  • Misaligned exhaust system
  • Strain on the exhaust system

Visual Inspection and Pre-checks

  • Inspect for loose, damaged, contaminated or incorrect components.
D1 CHECK THE EXHAUST SYSTEM FASTENERS
  • Check and confirm that all exhaust system fasteners on joining connections, hanger brackets and isolators are tightened to specification.

Was exhaust noise still present after confirming all exhaust system fasteners are tightened to specification?
Yes GO to D2
No The issue has been resolved.

D2 INSPECT THE EXHAUST ISOLATORS AND HANGER BRACKETS
  • Visually inspect the condition and alignment of all exhaust system isolators and hanger brackets.

Were exhaust system isolators and hanger brackets found to be in correct alginment and in good condition?
Yes GO to D3
No INSTALL new components as necessary.

D3 CHECK FOR MISSING OR DAMAGED EXHAUST HEAT SHIELDS
  • Check for noise originating from missing or damaged exhaust heat shields.

Were the exhaust heat shields found to be present and in correct alignment?
Yes GO to D4
No INSTALL new components as necessary.

D4 CHECK THE EXHAUST SYSTEM FOR ALIGNMENT
  • Manually move the exhaust system to simulate the bouncing action of the vehicle, checking for exhaust-to-body contact whilst the exhaust system is moving.

Was the exhaust noise seen to originate from contact between the exhaust system and the surrounding components/vehicle body?
Yes Ensure the exhaust system is installed correctly on the exhaust hangers and isolators. INSTALL new components as necessary.
No GO to D5

D5 CHECK THE EXHAUST SYSTEM FOR INTERNAL DAMAGE
  • Using a soft hammer or rubber mallet, lightly tap the resonators, mufflers, aftertreatment components and exhaust pipework, listening for loose internal baffling or internal damage.

Was noise such as rattling, clanging or twanging heard within the exhaust components?
Yes The exhaust component likely has internal damage. INSTALL new components as necessary.
No GO to D6

D6 CHECK THE EXHAUST SYSTEM FOR LEAKS
  • With the engine running, visually inspect the exhaust components and pipework for leaks.

Were leaks found?
Yes INSTALL new components as necessary.
No GO to D7

D7 CHECK FOR COOL DOWN PINGING
  • Run the engine and bring the exhaust system to operating temperature.
  • KOEO
  • While allowing the engine to cool, listen the exhaust system during coold down to attempt to isolate the noise complaint.

Was the exhaust complaint found to be cool down pinging?
Yes Cool down pinging is a result of the exhaust system expanding and contracting during heating and cooling. This is a normal condition. The issue has been resolved.
No The condition may be intermittent. Advise the customer no repair is required.

PINPOINT TEST RB : EXHAUST GAS TEMPERATURE (EGT) SENSOR

  WARNING: Manual regeneration of the particulate filter causes the exhaust gas to quickly get very hot. Initiate a manual regeneration only when the vehicle is on the ground with the area around the tailpipe free of people, obstructions, foreign material or other items. Failure to follow these instructions may result in serious personal injury.

NOTE: Regeneration may occur during normal operation. During regeneration, diagnostic procedures may display biased values. If a regeneration occurs during diagnostic procedures, allow the process to complete before continuing diagnostics.

Normal Operation and Fault Conditions

Refer to the DTC Fault Trigger Conditions.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
PCM P0544:00 Exhaust Gas Temperature Sensor Circuit - Bank 1 Sensor 1: No Sub Type Information Sets when the PCM detects, after 5 minutes of driving following a 6 hour soak, the exhaust gas temperature bank 1, sensor 1 sensor temperature does not correlate to the modeled temperature of 170ºC (338ºF). The PCM monitors the operation of the exhaust gas temperature bank 1, sensor 1 to determine if the sensor responds to the increase in temperature of the exhaust gas during vehicle operation. The PCM then compares the measured temperature to a modeled value.
PCM P0545:00 Exhaust Gas Temperature Sensor Circuit Low - Bank 1 Sensor 1: No Sub Type Information Sets when the PCM detects the exhaust gas temperature bank 1, sensor 1 voltage is less than 0.10 volt for greater than 15 seconds.
PCM P0546:00 Exhaust Gas Temperature Sensor Circuit High - Bank 1 Sensor 1: No Sub Type Information Sets when the PCM detects the exhaust gas temperature bank 1, sensor 1 voltage is greater than 4.90 volts for greater than 15 seconds.
PCM P0547:00 Exhaust Gas Temperature Sensor Circuit - Bank 2 Sensor 1: No Sub Type Information Sets when the PCM detects, after 5 minutes of driving following a 6 hour soak, the exhaust gas temperature bank 2, sensor 1 temperature does not correlate to the modeled temperature of 170ºC (338ºF). The PCM monitors the operation of the exhaust gas temperature bank 2, sensor 1 to determine if the sensor responds to the increase in temperature of the exhaust gas during vehicle operation. The PCM then compares the measured temperature to a modeled value.
PCM P0548:00 Exhaust Gas Temperature Sensor Circuit Low - Bank 2 Sensor 1: No Sub Type Information Sets when the PCM detects the exhaust gas temperature bank 2, sensor 1 voltage is less than 0.10 volt for greater than 15 seconds.
PCM P0549:00 Exhaust Gas Temperature Sensor Circuit High - Bank 2 Sensor 1: No Sub Type Information Sets when the PCM detects the exhaust gas temperature bank 2, sensor 1 voltage is greater than 4.90 volts for greater than 15 seconds.

Possible Sources

  • Exhaust leak
  • Exhaust gas temperature sensor circuitry concern
  • Exhaust gas temperature sensor (5J213)
  • PCM (12A650)
 Internet Explorer version 11 or greater is required to perform this Pinpoint Test.

    Diagnosis and Testing - Catalyst System

    Diagnostic Trouble Code (DTC) Chart Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.REFER to: Diagnostic Methods (100-00 General Information, Description and Operation)...

    Diagnosis and Testing - Particulate Filter System

    Diagnostic Trouble Code (DTC) Chart Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.REFER to: Diagnostic Methods (100-00 General Information, Description and Operation)...

    Other information:

    Lincoln Aviator 2020-2026 Service Manual: Diagnosis and Testing - DTC Chart and Pinpoint Tests


    Diagnostic Trouble Code (DTC) Chart Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).   Diagnostic Trouble Code Chart Module   DTC Description Action   ATCM B11D9:16 Vehicle Battery: Circuit Voltage Below Threshold   GO to Pinpoint Test A   ATCM B11D9:17 Vehicle Battery: Circuit Voltage Above Threshold   GO to Pinpoint Test A   ATCM U0140:00 Lost Communication With Body Control Module: No Sub Type Information   GO to Pinpoint Test B   ATCM U2002:9E Switch: Stuck On   GO to Pinpoint Test C   ATCM U2009:9E Rotary Encoder: Stuck On   GO to Pinpoint Test D   ATCM U3000:04 Control Module: System Internal Failure   GO to Pinpoint Test D   AWD C00A1:57 Driveline Control Module: Invalid / Incompatible Software Component   GO to Pinpoint Test E   AWD C00A1:F1 Driveline Control Module: <Manufacturer Defined>   GO to Pinpoint Test E   AWD C00A5:01 Driveline Control Module Transfer Case Unit Control Circuit Driver: General Electrical Failure   GO to Pinpoint Test E   AWD C00A5:08 Driveline Control Module Transfer Case Unit Control Circuit Driver: Bus Signal / Message Failure   GO to Pinpoint Test E   AWD C00A5:19 Driveline Control Module Transfer Case Unit Control Circuit Drive: Circuit Current Above Threshold   GO to Pinpoint Test E   AWD C00A5:1C Driveline Control Module Transfer Case Unit Control Circuit Driver: Circuit Voltage Out of Range   GO to Pinpoint Test E   AWD C00A5:49 Driveline Control Module Transfer Case Unit Control Circuit Drive: Internal Electronic Failure   GO to Pinpoint Test E   AWD C00A5:4B Driveline Control Module Transfer Case Unit Control Circuit Drive: Over Temperature   GO to Pinpoint Test E   AWD C00A5:96 Driveline Control Module Transfer Case Unit Control Circuit Drive: Component Internal Failure   GO to Pinpoint Test E   AWD C00A6:18 4WD/AWD Transfer Case Unit Actuator: Circuit Current Below Threshold   GO to Pinpoint Test F   AWD C00A6:19 4WD/AWD Transfer Case Unit Actuator: Circuit Current Above Threshold   GO to Pinpoint Test F   AWD C00A6:4B 4WD/AWD Transfer Case Unit Actuator: Over Temperature   GO to Pinpoint Test G   AWD C00A6:54 4WD/AWD Transfer Case Unit Actuator: Missing Calibration   GO to Pinpoint Test H   AWD C00A6:66 4WD/AWD Transfer Case Unit Actuator: Signal Has Too Many Transitions/Events   GO to Pinpoint Test I   AWD C00A6:71 4WD/AWD Transfer Case Unit Actuator: Actuator Stuck   GO to Pinpoint Test F   AWD C00A6:74 4WD/AWD Transfer Case Unit Actuator: Actuator Slipping   GO to Pinpoint Test F   AWD C00A6:99 4WD/AWD Transfer Case Unit Actuator: Exceeded Learning Limit   GO to Pinpoint Test F   AWD C00A7:11 4WD/AWD Transfer Case Unit Actuator Position Sensor "A": Circuit Short To Ground   GO to Pinpoint Test J   AWD C00A7:13 4WD/AWD Transfer Case Unit Actuator Position Sensor "A": Circuit Open   GO to Pinpoint Test J   AWD C00A7:17 4WD/AWD Transfer Case Unit Actuator Position Sensor "A": Circuit Voltage Above Threshold   GO to Pinpoint Test J   AWD C00A8:11 4WD/AWD Transfer Case Unit Actuator Position Sensor "B": Circuit Short To Ground   GO to Pinpoint Test K   AWD C00A8:13 4WD/AWD Transfer Case Unit Actuator Position Sensor "B": Circuit Open   GO to Pinpoint Test K   AWD C00A8:17 4WD/AWD Transfer Case Unit Actuator Position Sensor "B": Circuit Voltage Above Threshold   GO to Pinpoint Test K   AWD P0562:00 System Voltage Low: No Sub Type Information   GO to Pinpoint Test E   AWD P0563:00 System Voltage high: No Sub Type Information   GO to Pinpoint Test E   AWD P0603:00 Internal Control Module Keep Alive Memory (KAM) Error: No Sub Type Information   GO to Pinpoint Test E   AWD P0604:00 Internal Control Module Random Access Memory (RAM) Error: No Sub Type Information   GO to Pinpoint Test E   AWD P0605:00 Internal Control Module Read Only Memory (ROM) Error: No Sub Type Information   GO to Pinpoint Test E   AWD P0607:00 Control Module Performance: No Sub Type Information   GO to Pinpoint Test E   AWD P060A:00 Internal Control Module Monitoring Processor Performance: No Sub Type Information   GO to Pinpoint Test E   AWD P060B:00 Internal Control Module A/D Processing Performance: No Sub Type Information   GO to Pinpoint Test E   AWD P060C:00 Internal Control Module Main Processor Performance: No Sub Type Information   GO to Pinpoint Test E   AWD P0630:00 VIN Not Programmed or Incompatible - ECM/PCM: No Sub Type Information   GO to Pinpoint Test L   AWD P064F:00 Unauthorized Software/Calibration Detected: No Sub Type Information   GO to Pinpoint Test E   AWD P068A:00 ECM/PCM Power Relay De-Energized - Too Early: No Sub Type Information   GO to Pinpoint Test E   AWD P1001:00 KOER Not Able to Complete, KOER Aborted: No Sub Type Information   GO to Pinpoint Test M   AWD P1397:01 System Voltage Out Of Self-Test Range: General Electrical Failure   GO to Pinpoint Test M   AWD P1501:00 Vehicle Speed Sensor Out Of Self Test Range: No Sub Type Information   GO to Pinpoint Test M   AWD P160A:00 Control Module Vehicle Options Reconfiguration Error: No Sub Type Information   GO to Pinpoint Test L   AWD P166E:00 Internal control module all wheel drive discounnect control performance: No Sub Type Information   GO to Pinpoint Test N   AWD P1674:00 Control Module Software Corrupted: No Sub Type Information   GO to Pinpoint Test E   AWD P1705:00 Transmission Range Circuit Not Indicating Park/Neutral During Self-Test: No Sub Type Information   GO to Pinpoint Test M   AWD U0100:00 Lost Communication With ECM/PCM "A": No Sub Type Information   GO to Pinpoint Test O   AWD U0101:00 Lost Communication with TCM: No Sub Type Information   GO to Pinpoint Test O   AWD U0121:00 Lost Communication With Anti-Lock Brake System (ABS) Control Module "A": No Sub Type Information   GO to Pinpoint Test O   AWD U0126:00 Lost Communication With Steering Angle Sensor Module: No Sub Type Information   GO to Pinpoint Test O   AWD U0137:00 Lost Communication With Trailer Brake Control Module: No Sub Type Information   GO to Pinpoint Test O   AWD U0138:00 Lost Communication with All Terrain Control Module: No Sub Type Information   GO to Pinpoint Test O   AWD U0140:00 Lost Communication With Body Control Module: No Sub Type Information   GO to Pinpoint Test O   AWD U0146:00 Lost Communication With Serial Data Gateway "A": No Sub Type Information   GO to Pinpoint Test O   AWD U0151:00 Lost Communication With Restraints Control Module: No Sub Type Information   GO to Pinpoint Test O   AWD U0155:00 Lost Communication With Instrument Panel Cluster (IPC) Control Module: No Sub Type Information   GO to Pinpoint Test O   AWD U0164:00 Lost Communication With HVAC Control Module: No Sub Type Information   GO to Pinpoint Test O   AWD U0212:00 Lost Communication With Steering Column Control Module: No Sub Type Information   GO to Pinpoint Test O   AWD U0402:00 Invalid Data Received from TCM: No Sub Type Information   GO to Pinpoint Test P   AWD U0415:00 Invalid Data Received from Anti-Lock Brake System (ABS) Control Module "A": No Sub Type Information   GO to Pinpoint Test P   AWD U0422:00 Invalid Data Received From Body Control Module: No Sub Type Information   GO to Pinpoint Test P   AWD U0423:00 Invalid Data Received from Instrument Panel Cluster Control Module: No Sub Type Information   GO to Pinpoint Test P   AWD U0428:00 Invalid Data Received From Steering Angle Sensor Module: No Sub Type Information   GO to Pinpoint Test P   AWD U1012:00 Invalid Internal Control Module Monitoring Data Received from Anti-Lock Brake System (ABS) Control Module: No Sub Type Information   GO to Pinpoint Test P   AWD U1014:00 Invalid Internal Control Module Monitoring Data Received from Restraints Control Module: No Sub Type Information   GO to Pinpoint Test P   AWD U2100:00 Initial Configuration Not Complete: No Sub Type Information   GO to Pinpoint Test L   AWD U2101:00 Control Module Configuration Incompatible: No Sub Type Information   GO to Pinpoint Test L   AWD U2200:00 Control Module Configuration Memory Corrupt: No Sub Type Information   GO to Pinpoint Test L Global Customer Symptom Code (GCSC) Chart Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices...

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    Fastening the Seatbelts

    The front outboard and rear safety restraints in the vehicle are combination lap and shoulder belts.

    Insert the belt tongue into the proper buckle (the buckle closest to the direction the tongue is coming from) until you hear a snap and feel it latch. Make sure that you securely fasten the tongue in the buckle.

    Lincoln Aviator. Fastening the Seatbelts

    To unfasten, press the release button and remove the tongue from the buckle.

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