Test Procedure

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2007 Ford RV Cutaway, 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.

AZ1 PRELIMINARY DIAGNOSIS

Carry out a visual inspection.
Retrieve and record all DTCs.
Record the freeze frame data.
Are any DTCs other than DTC P2457 retrieved?

Yes	No
REFER toDIAGNOSTIC TROUBLE CODE (DTC) CHARTS AND DESCRIPTIONS .	GO to AZ2.

AZ2 CHECK FOR ENGINE OVERHEATING CONDITION

Check for engine overheating condition or loss of coolant condition. Refer to appropriate ENGINE COOLING article.
Is the engine overheating or losing coolant?

Yes	No
REFER to appropriate ENGINE COOLING article to diagnose the overheating or loss of coolant condition.	GO to AZ3.

AZ3 CHECK THE CAC SYSTEM FOR DAMAGE

Check the CAC system for:
- air restrictions
- debris
- damaged clamps
- damaged cooler fins
- damaged hose
- leaks
Is the CAC system operating correctly?

Yes	No
GO to AZ4.	REPAIR or INSTALL a new component as necessary. REFER to appropriate CHARGE AIR COOLER article. CLEAR the DTCs. REPEAT the self-test.

AZ4 RECREATE EGR COOLER PERFORMANCE CONDITIONS

Clear the PCM DTCs.
Road test the vehicle to recreate the EGR cooler performance condition DTC P2457 using the freeze frame data.
Retrieve and record the PCM continuous DTCs.
Is DTC P2457 retrieved?

Yes	No
GO to AZ5.	If any other DTCs are retrieved, REFER toDIAGNOSTIC TROUBLE CODE (DTC) CHARTS AND DESCRIPTIONS . If no DTCs are retrieved, the system is operating correctly at this time. The concern may be intermittent. CHECK for a loose connection, and damaged or corroded terminals. WIGGLE the harness attempting to recreate the concern. REPAIR as necessary. REFER to the SYMPTOM CHARTS article, Symptom Charts, if a driveability concern exists.

Yes

GO to AZ5.

If any other DTCs are retrieved, REFER toDIAGNOSTIC TROUBLE CODE (DTC) CHARTS AND DESCRIPTIONS .
If no DTCs are retrieved, the system is operating correctly at this time. The concern may be intermittent. CHECK for a loose connection, and damaged or corroded terminals. WIGGLE the harness attempting to recreate the concern. REPAIR as necessary. REFER to the SYMPTOM CHARTS article, Symptom Charts, if a driveability concern exists.

AZ5 CHECK THE EGR COOLER FOR RESTRICTIONS

Remove the EGR cooler. Refer to appropriate EXHAUST EMISSION CONTROL article.
Check the EGR cooler exhaust port, coolant port and coolant hose for restrictions.
Is the EGR cooler exhaust port restricted?

Yes	No
REPAIR the restricted EGR cooler exhaust port or INSTALL a new EGR cooler as necessary. REFER to appropriate EXHAUST EMISSION CONTROL article. CLEAR the DTCs. REPEAT the self-test.	REPAIR the restricted EGR cooler coolant port or coolant hose as necessary. INSTALL a new EGR cooler or coolant hose as necessary. CLEAR the DTCs. REPEAT the self-test.