Hi All,

First post on here. I have recently completed a engine swap on a 2012 CX-5 Diesel 2.2L. The original engine had a broken oil pump chain, we all know is a common issue. The replacement engine went in without any major issues and sounds, drives, heats and cools fine, and gearbox shifts smooth. However, when driving the vehicle i have experienced five occurrences of what i would consider a malfunction with one or more of the systems, unrelated to the engine. Here is whats going on:

Driving along at constant speed, with no traffic in front of me. All of a sudden, it feels like the breaking system is auto breaking and/or something weird is going on with the gearbox. Just about all the light on the cluster light up with the major warnings on the cluster being: SCBS, TMPS, Traction control, engine check light and the red hazard light (see pics below), throttle response then feels to be computer controlled into a limp mode - i definitely cannot apply throttle and get any boost from turochargers. I pull over, put the vehicle in park, engine idling, Turn engine off, then restart, engine check light is on solid, other warnings have gone away, put the vehcile in drive, throttle response seems normal, breaking etc, vehcile drives normal (engine check light on), until the malfunction happens again.

I have tried to reproduce this situation but i cant seem to pin it down to a specific speed, or breaking or loading. The vehicle has done this five times in two test drives at speeds of 40Kph to 90Kph, cruising speed, no acceleration or decelleration.

Any help would be much appreciated.

 

1st step is always scanning it for fault codes.

 

Absolutely. heres the output from FORScan, i cleared all codes before a new testdrive, and then drove the vehicle until the issue happened again. This is the capture from the latest event driving along the highway:

------===TCM DTC U0442:00-6C===
Code: U0442 - Invalid Data Received From ECM/PCM B

Status:
- DTC Maturing - Intermittent at Time of Request
- Malfunction Indicator Lamp is Off for this DTC
- Test not complete

Module: Transmission Control Module

Freeze Frame #1:
-DTC: --- - DTC That Caused Required Snapshot Data Storage
-LOAD: 26.67 % - Calculated Load Value
-ECT: 83 °C - Engine coolant temperature
-RPM: 1952 1/min - Engine Revolutions Per Minute
-VSS: 103.0 km/h - Vehicle Speed
-IAT: 29 °C - Intake Air Temperature
-TP: 81.96 % - Throttle Position
-RUNTM: 940 s - Time Since Engine Start
-VPWR: 14.11 V - Control Module Voltage
-APP_D: 23.14 % - Accelerator Pedal Position D
-APP: 23.00 % - Accelerator Pedal Position
-APP: 23.00 % - Accelerator Pedal Position
-SLIP_VALUE: 7 1/min - Absolute Value of Slip
-HTM_DIS: 0.0 km - The distance travelled since the High Temperature Mode was activated.
-HTM_DIS: 0.0 km - The distance travelled since the High Temperature Mode was activated.
-GEAR_SEL: 5 - Gear select position
-GEAR_SEL: 5 - Gear select position
-TSS: 1951 1/min - Turbine Shaft Speed
-TSS: 1951 1/min - Turbine Shaft Speed
-OSS: 3250 1/min - Output Shaft Speed.
-OSS: 3250 1/min - Output Shaft Speed.
-TFT: 87 °C - Transmission Fluid Temperature
-TFT: 87 °C - Transmission Fluid Temperature
-LOCK_UP: ON - Toruque Converter Lockup State
-LOCK_UP: ON - Toruque Converter Lockup State
-SS_ON-OFF: Off - ON/OFF solenoid
-SS_ON_OFF: Off - ON/OFF solenoid
-OIL_PRES_SW2: On - Oil Pressure Switch 2
-OIL_PRES_SW1: Off - Oil Pressure Switch 1
-OP_SW2: On - Oil Pressure Switch 2
-OP_SW1: Off - Oil Pressure Switch 1
-EOP: Off - Electric Oil Pump
-TORQUE_DES: 460.0 Nm - Desired Engine Torque
-G_INHIBIT_R: Off - Gear Inhibit - Reverse Range
-G_INHIBIT_N: Off - Gear Inhibit - Neutral Range
-G_INHIBIT_6: Off - Gear Inhibit - 6th Gear
-G_INHIBIT_5: Off - Gear Inhibit - 5th Gear
-G_INHIBIT_4: Off - Gear Inhibit - 4th Gear
-G_INHIBIT_3: Off - Gear Inhibit - 3rd Gear
-G_INHIBIT_2: Off - Gear Inhibit - 2nd Gear
-G_INHIBIT_1: Off - Gear Inhibit - 1st Gear
-OIL_PRES_SW4: On - Oil Pressure Switch 4
-OIL_PRES_SW3: Off - Oil Pressure Switch 3
-EOP_RLY: Off - Electric Oil Pump Relay
-OP_SW4: On - Oil Pressure Switch 4
-OP_SW3: Off - Oil Pressure Switch 3
-EOP_RLY: Off - Electric Oil Pump Relay
-UPSHIFT_REV: Off - Upshift Record By Engine Request

===END TCM===

===PCM DTC P2033:00-EC===
Code: P2033 - Exhaust Gas Temperature Sensor Circuit High Bank 1 Sensor 2

Status:
- DTC Maturing - Intermittent at Time of Request
- Malfunction Indicator Lamp is On for this DTC
- Test not complete

Module: Powertrain Control Module

Freeze Frame #1:
-DTC: --- - DTC That Caused Required Snapshot Data Storage
-LOAD: 26.27 % - Calculated Load Value
-ECT: 83 °C - Engine coolant temperature
-RPM: 1969 1/min - Engine Revolutions Per Minute
-VSS: 107.0 km/h - Vehicle Speed
-IAT: 29 °C - Intake Air Temperature
-MAF: 6.73 g/s - Mass Air Flow
-TP: 82.35 % - Throttle Position
-ISV_POS: 82.35 % - Intake Shatter Valve Position
-RUNTM: 939 s - Time Since Engine Start
-FRP: 164580.0 kPa - Fuel Rail Pressure
-FLI: 45.10 % - Fuel Level
-WARM_UPS: 1 - Number Of Warm-ups Since DTCs Cleared
-CLR_DIST: 32.0 km - Distance since diagnostic trouble codes cleared
-BARO: 102.0 kPa - Barometric pressure
-VPWR: 13.91 V - Control Module Voltage
-TP_REL: 82.35 % - Relative Throttle Position
-AAT: 29 °C - Ambient Air Temperature
-IAT: 29 °C - Intake Air Temperature
-APP_D: 22.75 % - Accelerator Pedal Position D
-APP_E: 20.78 % - Accelerator Pedal Position E
-TAC_PCT: 82.35 % - Commanded Throttle Actuator Control
-ISV_DSD: 82.35 % - Intake Shatter Valve Control Desired
-FRP_ABS: 164580.0 kPa - Fuel Rail Pressure (Absolute)
-APP_REL: 22.75 % - Accelerator Pedal Position Relative
-EOT: 92 °C - Engine Oil Temperature
-ECT2_SUP: Yes - Engine Coolant Temperature Sensor 1 supported
-ECT1_SUP: Yes - Engine Coolant Temperature Sensor 1 supported
-ECT2: 135 °C - Engine Coolant Temperature 2 - Voltage
-ECT1: 83 °C - Engine Coolant Temperature Sensor 1

===END PCM===

===PCM DTC P1303:00-6C===
Code: P1303 - EGR Calibration Fault

Status:
- DTC Maturing - Intermittent at Time of Request
- Malfunction Indicator Lamp is Off for this DTC
- Test not complete

Module: Powertrain Control Module

Freeze Frame #1:
-DTC: --- - DTC That Caused Required Snapshot Data Storage
-LOAD: 34.90 % - Calculated Load Value
-ECT: 85 °C - Engine coolant temperature
-RPM: 0 1/min - Engine Revolutions Per Minute
-VSS: 0.0 km/h - Vehicle Speed
-IAT: 32 °C - Intake Air Temperature
-MAF: 0.16 g/s - Mass Air Flow
-TP: 89.41 % - Throttle Position
-ISV_POS: 89.41 % - Intake Shatter Valve Position
-RUNTM: 0 s - Time Since Engine Start
-FRP: 3810.0 kPa - Fuel Rail Pressure
-FLI: 12.94 % - Fuel Level
-WARM_UPS: 0 - Number Of Warm-ups Since DTCs Cleared
-CLR_DIST: 10.0 km - Distance since diagnostic trouble codes cleared
-BARO: 102.0 kPa - Barometric pressure
-VPWR: 13.21 V - Control Module Voltage
-TP_REL: 89.80 % - Relative Throttle Position
-AAT: 32 °C - Ambient Air Temperature
-IAT: 32 °C - Intake Air Temperature
-APP_D: 0.00 % - Accelerator Pedal Position D
-APP_E: 0.00 % - Accelerator Pedal Position E
-TAC_PCT: 82.35 % - Commanded Throttle Actuator Control
-ISV_DSD: 82.35 % - Intake Shatter Valve Control Desired
-FRP_ABS: 3810.0 kPa - Fuel Rail Pressure (Absolute)
-APP_REL: 0.00 % - Accelerator Pedal Position Relative
-EOT: 90 °C - Engine Oil Temperature
-ECT2_SUP: Yes - Engine Coolant Temperature Sensor 1 supported
-ECT1_SUP: Yes - Engine Coolant Temperature Sensor 1 supported
-ECT2: 135 °C - Engine Coolant Temperature 2 - Voltage
-ECT1: 85 °C - Engine Coolant Temperature Sensor 1

===END PCM===

===OBDII DTC P2033-C===
Code: P2033 - Exhaust Gas Temperature Sensor Circuit High Bank 1 Sensor 2

Status:
- Confirmed - malfunction is confirmed

Module: On Board Diagnostic II
===END OBDII===

===ICA DTC U0401:68-28===
Code: U0401 - Invalid Data Received from ECM/PCM A

Additional Fault Symptom:
- Event Information

Status:
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Smart City Brake Support

Freeze Frame #1:
-EVENT_TIME: 322250365 s (Sun Oct 26 17:35:31 2036) - Event time
-TOTAL_DISTANCE: 141502 km - Total Distance

===END ICA===

===ICA DTC U0415:68-28===
Code: U0415 - Invalid Data Received from Anti-Lock Brake System (ABS) Control Module 'A'

Additional Fault Symptom:
- Event Information

Status:
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Smart City Brake Support

Freeze Frame #1:
-EVENT_TIME: 322250366 s (Sun Oct 26 17:35:32 2036) - Event time
-TOTAL_DISTANCE: 141502 km - Total Distance

===END ICA===

===4X4M DTC U0401:68-08===
Code: U0401 - Invalid Data Received from ECM/PCM A

Additional Fault Symptom:
- Event Information

Status:
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: 4X4 Control Module

Freeze Frame #1:
-EVENT_TIME: 322250369 s (Sun Oct 26 17:35:35 2036) - Event time
-TOTAL_DISTANCE: 141502 km - Total Distance
-MODULE_VOLTAGE: 14.2 V - Control Module Voltage
-OUTDOOR_TEMPERATURE: 24 °C - Outside temperature
-PWR_MODE_KEY: Running (Position 2) - Power Mode Key State
-IG-ON_TIMER: 944 s - Times Since Ignition Switch ON

===END 4X4M===

===ABS DTC U0401:00-68===
Code: U0401 - Invalid Data Received from ECM/PCM A

Status:
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC
- Test not complete

Module: Antilock braking system

Freeze Frame #1:
-EVENT_TIME: 322250365 s (Sun Oct 26 17:35:31 2036) - Event time
-TOTAL_DISTANCE: 141502 km - Total Distance
-MODULE_VOLTAGE: 14.2 V - Control Module Voltage
-OUTDOOR_TEMPERATURE: 24 °C - Outside temperature
-PWR_MODE_KEY: Running (Position 2) - Power Mode Key State
-VSPD_STATUS: Over 10 km/h - Vehicle Speed Status
-SHIFT_STATUS: D - Shift Position Status
-RPM_STATUS: Over 1500 rpm - Engine RPM Status
-ECT_STATUS: Over 80 degrees C - Engine Coolant Temperature Status
-CFG_STATUS: Config Complete - Configuration Status
-APP_STATUS: Over 20% - Accelerator Pedal Position Status
-IG-ON_TIMER: 939 s - Times Since Ignition Switch ON

===END ABS===

===RCM DTC ===
Successful DTC reading, no error codes found

Module: Restraint Control Module
===END RCM===

===AFS DTC ===
Successful DTC reading, no error codes found

Module: Adaptive Front Lighting System
===END AFS===

===SSU DTC ===
Successful DTC reading, no error codes found

Module: Start Stop Unit
===END SSU===

===EPS DTC ===
Successful DTC reading, no error codes found

Module: Electronic-Controlled Power Steering
===END EPS===

===F_BCM DTC ===
Successful DTC reading, no error codes found

Module: Front Body Control Module
===END F_BCM===

===IC DTC ===
Successful DTC reading, no error codes found

Module: Instrument Cluster
===END IC===

 

What is the condition of the battery? Ii don’t mean how old it is, have it load tested by a competent shop or auto parts store. Many of the items the OP sees could be caused by a weak battery - it’s an easy check anyway.




.

 

If the battery tests good, I would ignore the U codes, I would be removing the EGR &/or associated pipes to see how much carbon build up is preset.

 

The battery i would consider "healthy". It was charged up to float before the replacement engine was started. Its been a solid battery and has never had any flats or low voltages.

Ok so a little update:

I replaced the "EXHAUST GAS PRESSURE SENSOR" the sensor on the rear cam cover with the single pipe going down to the turbo. Has been updated a few times to part "SHY6-18-W00", I used the sensor off the original engine. This sensor i assumed to be working correctly as the previous engine didn't give any codes and was funning fine before the oil pump chain snapped.

Fitted sensor, then drove briefly on the highway, seems ok,
Checked the codes with TEXA --> there was an EGR calibration malfunction code, but no engine check light. Issue had not turned up at this point.
Upon driving on highway again at cruising speed. The Issue develops and full set of cluster lights an engine check come on.

I then replaced the EGR Value (that bolts onto the intake manifold), with the unit from the engine that was removed (working unit, had no codes on this vehicle). This valve was also cleaned to remove any buildup of carbon. Took it for a drive, checked the codes with TEXA, (nothing), drove a bit more on the highway after about 30 mins of driving, Same issue develops at cruising speed between 50-100Kph (30-60mph).

Im out of ideas?

Currently im getting 2033 code from FORScan:

 

Ok so ill close and answer this thread. Turns out one of the exhaust temp sensors was unplugged. I guess it just goes to show no matter how many times you check connections and make sure everything is connected, you can always mis something.