Powertrain Malfunction / Reduced Power error after Intercooler Install

[BigST22]

I’ve owned 2022 Explorer ST for a couple years, stock, and problem free. Today, I unplugged the battery, and installed the CVFabrications Intercooler. I removed the grill shutters. Took my time putting everything back together. I thought I connected, and tightened everything well. Upon initial startup, I got 2 codes: Powertrain Malfunction / Reduced Power, and Pre-Collision Assist not available. Drove down the block and power was clearly choppy. Annoyed I spent a day doing install only to have major new issues. Any ideas?

 

[UNBROKEN]

Ideas? Yep…they’re self induced issues.
Go back through every plug and check not only that they’re tight and locked in but make sure you didn’t push a pin out of place. Find that issue and you’ll fix your issue.

 

[FORZDA3]

Yes, you failed to mate all the connectors you disconnected. There are several.

 

[Chamorro85]

They've all said it. I had this problem with my Fusion Sport. Did a quick test drive after installing FMIC before putting the bumper back on. Make sure boost didn't pop a pipe off. Put it all back together and everything turned off right away except one. I forgot a temp sensor that made the system go crazy.

It can be something super easy. I did a test startup with this car as well and went super slow on reinstalling to make sure I didn't miss anything this time. Just work backwards and double check. You'll find the plug you missed.

 

[Frankenstein]

I’ve owned 2022 Explorer ST for a couple years, stock, and problem free. Today, I unplugged the battery, and installed the CVFabrications Intercooler. I removed the grill shutters. Took my time putting everything back together. I thought I connected, and tightened everything well. Upon initial startup, I got 2 codes: Powertrain Malfunction / Reduced Power, and Pre-Collision Assist not available. Drove down the block and power was clearly choppy. Annoyed I spent a day doing install only to have major new issues. Any ideas?

Did you find the problem? I finally installed my intercooler, aFe intake, and FenFab charge pipe today, but now I'm having the same issues you described. I'll go through and check it all again tomorrow either way.

 

[Frankenstein]

Did you find the problem? I finally installed my intercooler, aFe intake, and FenFab charge pipe today, but now I'm having the same issues you described. I'll go through and check it all again tomorrow either way.

I'd missed the large connector at lower driver side, no more limp mode but it definitely needs a new tune. I also have a park assist failure now, even after double-checking both sides. It had been acting up for a while so I may just leave it.

 

[BigST22]

I just took apart and slowly reassembled. I had missed the small clip on the Intercooler sensor, dumb. No more Powertrain Malfunction or front sensor code, ST seems to run just fine on short test drive, although I have new codes:
P007D
P0128
P0238
P05a1
I did remove most of the shutters
U0253
Not sure what to do at this point.

 

[FORZDA3]

I didn’t look up those codes, but you can turn off the shutter notices and other codes in the tune file.

 

[BigST22]

I sent codes to GooseTuned and will see if it simply a matter of clearing those codes.

 

[FORZDA3]

I sent codes to GooseTuned and will see if it simply a matter of clearing those codes.

Yep, Goose will get it sorted out for you for sure.

 

[BigST22]

Interesting thing happened. Drove the car twice more, and the check engine light and codes now cleared. Seems we’re all good to go, time to throw on the tune!