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Test Procedure

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  1. 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 to DIAGNOSTIC TROUBLE CODE (DTC) DESCRIPTIONS . GO to  AZ2.
  2. AZ2 CHECK FOR ENGINE OVERHEATING CONDITION 
    • Check for engine overheating condition or loss of coolant condition. Refer to ENGINE COOLING .

    Is the engine overheating or losing coolant? 

    Yes No
    REFER to ENGINE COOLING to diagnose the overheating or loss of coolant condition. GO to  AZ3.
  3. AZ3 CHECK THE CHARGE AIR COOLER (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 INTAKE AIR DISTRIBUTION AND FILTERING .
    CLEAR the DTCs. REPEAT the self-test.
  4. 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 to DIAGNOSTIC TROUBLE CODE (DTC) 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 SYMPTOM CHARTS , if a driveability concern exists.
  5. AZ5 CHECK THE EGR COOLER FOR RESTRICTIONS 
    • Remove the EGR cooler. Refer to ENGINE EMISSION CONTROL .
    • 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. 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. CLEAR the DTCs. REPEAT the self-test.
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