DTC P2495:00 [PCM (SKYACTIV-D 2.2)]

id0102j5215000

DTC P2495:00

EGR cooler bypass valve position sensor: High input

DETECTION CONDITION

•  With the following conditions met, the output voltage of the EGR cooler bypass valve position sensor exceeds 4.87 V for a continuous 2.5 s.

―  Battery positive voltage: 8—16 V

―  0.5 s or more have elapsed after ignition is switched ON (engine off or on)

―  The following DTCs are not detected

•  Constant voltage power supply control system: P0652:00, P0653:00

Diagnostic support note

•  This is a continuous monitor (CCM).

•  The check engine light illuminates if the PCM detects the above malfunction condition during the first drive cycle.

•  FREEZE FRAME DATA/Snapshot data is available.

•  DTC is stored in the PCM memory.

FAIL-SAFE FUNCTION

•  Limits engine torque.

•  Inhibits the automatic diesel particulate filter regeneration control.

•  Inhibits the manual diesel particulate filter regeneration control.

•  Inhibits the EGR control.

POSSIBLE CAUSE

•  EGR cooler bypass valve/EGR cooler bypass valve position sensor connector or terminal malfunction

•  PCM connector or terminal malfunction

•  Short to power supply in wiring harness between EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal F and PCM terminal 1AV

•  Short circuit in EGR cooler bypass valve position sensor power supply circuit and signal circuit

•  Open circuit in wiring harness between the following terminals:

―  EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal F and PCM terminal 1AV

―  EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal D and PCM terminal 1AT

•  EGR cooler bypass valve position sensor malfunction

•  PCM malfunction

DTC P2495:00	EGR cooler bypass valve position sensor: High input
DETECTION CONDITION	• With the following conditions met, the output voltage of the EGR cooler bypass valve position sensor exceeds 4.87 V for a continuous 2.5 s. ― Battery positive voltage: 8—16 V ― 0.5 s or more have elapsed after ignition is switched ON (engine off or on) ― The following DTCs are not detected • Constant voltage power supply control system: P0652:00, P0653:00 Diagnostic support note • This is a continuous monitor (CCM). • The check engine light illuminates if the PCM detects the above malfunction condition during the first drive cycle. • FREEZE FRAME DATA/Snapshot data is available. • DTC is stored in the PCM memory.
FAIL-SAFE FUNCTION	• Limits engine torque. • Inhibits the automatic diesel particulate filter regeneration control. • Inhibits the manual diesel particulate filter regeneration control. • Inhibits the EGR control.
POSSIBLE CAUSE	• EGR cooler bypass valve/EGR cooler bypass valve position sensor connector or terminal malfunction • PCM connector or terminal malfunction • Short to power supply in wiring harness between EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal F and PCM terminal 1AV • Short circuit in EGR cooler bypass valve position sensor power supply circuit and signal circuit • Open circuit in wiring harness between the following terminals: ― EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal F and PCM terminal 1AV ― EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal D and PCM terminal 1AT • EGR cooler bypass valve position sensor malfunction • PCM malfunction

Diagnostic Procedure

Step

Inspection

Results

Action

1

RECORD VEHICLE STATUS WHEN DTC WAS DETECTED TO UTILIZE WITH REPEATABILITY VERIFICATION

Note

•  Recording can be facilitated using the screen capture function of the PC.

•  Record the freeze frame data/snap shot data.

—

Go to the next step.

2

INSPECT EGR COOLER BYPASS VALVE/EGR COOLER BYPASS VALVE POSITION SENSOR CONNECTOR CONDITION

•  Switch the ignition OFF.

•  Disconnect the EGR cooler bypass valve/EGR cooler bypass valve position sensor connector.

•  Inspect the connector engagement and connection condition, and inspect the terminals for damage, deformation, corrosion, or disconnection.

•  Is the connector normal?

Yes

Go to the next step.

No

Repair or replace the connector, then go to Step 8.

3

INSPECT PCM CONNECTOR CONDITION

•  Disconnect the PCM connector.

•  Inspect the connector engagement and connection condition, and inspect the terminals for damage, deformation, corrosion, or disconnection.

•  Is the connector normal?

Yes

Go to the next step.

No

Repair or replace the connector, then go to Step 8.

4

INSPECT EGR COOLER BYPASS VALVE POSITION SENSOR SIGNAL CIRCUIT FOR SHORT TO POWER SUPPLY

•  Verify that the EGR cooler bypass valve/EGR cooler bypass valve position sensor connector and the PCM connector are disconnected.

•  Switch the ignition ON (engine off).

•  Measure the voltage at EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal F (vehicle wiring harness side).

•  Is the voltage 0 V?

Yes

Go to the next step.

No

Refer to the wiring diagram and verify if there is a common connector between EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal F and PCM terminal 1AV.

If there is a common connector:

•  Inspect the common connector and terminals for corrosion, damage, or disconnection and the common wiring harnesses for short to power supply to determine the malfunctioning location.

•  Repair or replace the malfunctioning location.

If there is no common connector:

•  Repair or replace the wiring harness which is shorted to the power supply.

Go to Step 8.

5

INSPECT EGR COOLER BYPASS VALVE POSITION SENSOR POWER SUPPLY CIRCUIT AND SIGNAL CIRCUIT FOR SHORT CIRCUIT

•  Verify that the EGR cooler bypass valve/EGR cooler bypass valve position sensor connector and the PCM connector are disconnected.

•  Switch the ignition OFF.

•  Inspect for continuity between EGR cooler bypass valve/EGR cooler bypass valve position sensor terminals B and F (vehicle wiring harness side).

•  Is there continuity?

Yes

Refer to the wiring diagram and verify if there is a common connector between the following terminals.

•  EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal B and PCM terminal 1AU

•  EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal F and PCM terminal 1AV

If there is a common connector:

•  Inspect the common connector and terminals for corrosion, damage, or disconnection and the common wiring harnesses for short circuit to determine the malfunctioning location.

•  Repair or replace the malfunctioning location.

If there is no common connector:

•  Repair or replace the malfunctioning wiring harness.

Go to Step 8.

No

Go to the next step.

6

INSPECT EGR COOLER BYPASS VALVE POSITION SENSOR CIRCUIT FOR OPEN CIRCUIT

•  Verify that the EGR cooler bypass valve/EGR cooler bypass valve position sensor connector and the PCM connector are disconnected.

•  Inspect between the following terminals (vehicle wiring harness side) for continuity.

―  EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal F and PCM terminal 1AV

―  EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal D and PCM terminal 1AT

•  Is there continuity?

Yes

Go to the next step.

No

Refer to the wiring diagram and verify if there is a common connector between the following terminals.

•  EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal F and PCM terminal 1AV

•  EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal D and PCM terminal 1AT

If there is a common connector:

•  Inspect the common connector and terminals for corrosion, damage, or disconnection and the common wiring harnesses for an open circuit to determine the malfunctioning location.

•  Repair or replace the malfunctioning location.

If there is no common connector:

•  Repair or replace the wiring harness which has an open circuit.

Go to Step 8.

7

INSPECT EGR COOLER BYPASS VALVE POSITION SENSOR

•  Reconnect all the disconnected connectors.

•  Inspect the EGR cooler bypass valve position sensor.
(See EGR COOLER BYPASS VALVE POSITION SENSOR INSPECTION [SKYACTIV-D 2.2])

•  Is the EGR cooler bypass valve position sensor normal?

Yes

Go to the next step.

No

Replace the EGR cooler bypass valve, then go to the next step.

(See EGR COOLER BYPASS VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2])

8

VERIFY THAT REPAIRS HAVE BEEN COMPLETED

•  Reconnect all the disconnected connectors.

•  Refer to the [MEMORY CLEARING PROCEDURE] and clear the DTC.
(See CLEARING DTC [PCM (SKYACTIV-D 2.2)])

•  Switch the ignition ON (engine off) or leave for 10 s while idling.

•  Display the DTCs using the M-MDS.
(See DTC TABLE [PCM (SKYACTIV-D 2.2)])

•  Has DTC P2495:00 been recorded?

Yes

Repeat the inspection from Step 1.

•  If the malfunction recurs, replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [SKYACTIV-D 2.2])

No

Go to the next step.

9

VERIFY OTHER DTCs

•  Has any other DTC or pending code been stored?

Yes

Repair the malfunctioning location according to the applicable DTC troubleshooting.

(See DTC TABLE [PCM (SKYACTIV-D 2.2)])

No

DTC troubleshooting completed.

Step	Inspection	Results	Action
1	RECORD VEHICLE STATUS WHEN DTC WAS DETECTED TO UTILIZE WITH REPEATABILITY VERIFICATION Note • Recording can be facilitated using the screen capture function of the PC. • Record the freeze frame data/snap shot data.	—	Go to the next step.
2	INSPECT EGR COOLER BYPASS VALVE/EGR COOLER BYPASS VALVE POSITION SENSOR CONNECTOR CONDITION • Switch the ignition OFF. • Disconnect the EGR cooler bypass valve/EGR cooler bypass valve position sensor connector. • Inspect the connector engagement and connection condition, and inspect the terminals for damage, deformation, corrosion, or disconnection. • Is the connector normal?	Yes	Go to the next step.
2		No	Repair or replace the connector, then go to Step 8.
3	INSPECT PCM CONNECTOR CONDITION • Disconnect the PCM connector. • Inspect the connector engagement and connection condition, and inspect the terminals for damage, deformation, corrosion, or disconnection. • Is the connector normal?	Yes	Go to the next step.
3		No	Repair or replace the connector, then go to Step 8.
4	INSPECT EGR COOLER BYPASS VALVE POSITION SENSOR SIGNAL CIRCUIT FOR SHORT TO POWER SUPPLY • Verify that the EGR cooler bypass valve/EGR cooler bypass valve position sensor connector and the PCM connector are disconnected. • Switch the ignition ON (engine off). • Measure the voltage at EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal F (vehicle wiring harness side). • Is the voltage 0 V?	Yes	Go to the next step.
4		No	Refer to the wiring diagram and verify if there is a common connector between EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal F and PCM terminal 1AV. If there is a common connector: • Inspect the common connector and terminals for corrosion, damage, or disconnection and the common wiring harnesses for short to power supply to determine the malfunctioning location. • Repair or replace the malfunctioning location. If there is no common connector: • Repair or replace the wiring harness which is shorted to the power supply. Go to Step 8.
5	INSPECT EGR COOLER BYPASS VALVE POSITION SENSOR POWER SUPPLY CIRCUIT AND SIGNAL CIRCUIT FOR SHORT CIRCUIT • Verify that the EGR cooler bypass valve/EGR cooler bypass valve position sensor connector and the PCM connector are disconnected. • Switch the ignition OFF. • Inspect for continuity between EGR cooler bypass valve/EGR cooler bypass valve position sensor terminals B and F (vehicle wiring harness side). • Is there continuity?	Yes	Refer to the wiring diagram and verify if there is a common connector between the following terminals. • EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal B and PCM terminal 1AU • EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal F and PCM terminal 1AV If there is a common connector: • Inspect the common connector and terminals for corrosion, damage, or disconnection and the common wiring harnesses for short circuit to determine the malfunctioning location. • Repair or replace the malfunctioning location. If there is no common connector: • Repair or replace the malfunctioning wiring harness. Go to Step 8.
5		No	Go to the next step.
6	INSPECT EGR COOLER BYPASS VALVE POSITION SENSOR CIRCUIT FOR OPEN CIRCUIT • Verify that the EGR cooler bypass valve/EGR cooler bypass valve position sensor connector and the PCM connector are disconnected. • Inspect between the following terminals (vehicle wiring harness side) for continuity. ― EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal F and PCM terminal 1AV ― EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal D and PCM terminal 1AT • Is there continuity?	Yes	Go to the next step.
6		No	Refer to the wiring diagram and verify if there is a common connector between the following terminals. • EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal F and PCM terminal 1AV • EGR cooler bypass valve/EGR cooler bypass valve position sensor terminal D and PCM terminal 1AT If there is a common connector: • Inspect the common connector and terminals for corrosion, damage, or disconnection and the common wiring harnesses for an open circuit to determine the malfunctioning location. • Repair or replace the malfunctioning location. If there is no common connector: • Repair or replace the wiring harness which has an open circuit. Go to Step 8.
7	INSPECT EGR COOLER BYPASS VALVE POSITION SENSOR • Reconnect all the disconnected connectors. • Inspect the EGR cooler bypass valve position sensor. (See EGR COOLER BYPASS VALVE POSITION SENSOR INSPECTION [SKYACTIV-D 2.2]) • Is the EGR cooler bypass valve position sensor normal?	Yes	Go to the next step.
7		No	Replace the EGR cooler bypass valve, then go to the next step. (See EGR COOLER BYPASS VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2])
8	VERIFY THAT REPAIRS HAVE BEEN COMPLETED • Reconnect all the disconnected connectors. • Refer to the [MEMORY CLEARING PROCEDURE] and clear the DTC. (See CLEARING DTC [PCM (SKYACTIV-D 2.2)]) • Switch the ignition ON (engine off) or leave for 10 s while idling. • Display the DTCs using the M-MDS. (See DTC TABLE [PCM (SKYACTIV-D 2.2)]) • Has DTC P2495:00 been recorded?	Yes	Repeat the inspection from Step 1. • If the malfunction recurs, replace the PCM, then go to the next step. (See PCM REMOVAL/INSTALLATION [SKYACTIV-D 2.2])
8		No	Go to the next step.
9	VERIFY OTHER DTCs • Has any other DTC or pending code been stored?	Yes	Repair the malfunctioning location according to the applicable DTC troubleshooting. (See DTC TABLE [PCM (SKYACTIV-D 2.2)])
9		No	DTC troubleshooting completed.