Powertrain, generic (extended)

P2C22 Exhaust Heat Exchanger Exhaust Bypass Valve A Position Sensor Circuit

Check engine lightOn
EmissionsRelevant
Drive cycleNot required
Limp modeNo

Full hybrids with exhaust heat recovery pass hot exhaust through a coolant heat exchanger after a cold start and divert it around the exchanger with flap A once enough heat has been gathered. A sensor in the flap actuator reports the flap angle to the engine module. P2C22 is the general electrical fault of that feedback: the signal is missing or cannot be read. Ford uses it on its full hybrids. SSM 51921 ties P2C22 with P237C/P237D on the 2022–2023 Maverick 2.5L to water inside the heat exchanger, which is replaced; on 2021–2023 F-150 3.5L PowerBoost trucks SSM 52050 blames the bypass control valve and replaces the muffler inlet pipe, and SSM 53003 supplies an actuator kit. The MIL lights; P2C24/P2C25 name low and high signals, P2C23 an implausible one.

Likely causes

Water intrusion into the heat exchanger or its actuator (Ford Maverick hybrid)
Failed bypass valve actuator with integrated position sensor
Corroded or loose connector at the actuator under the vehicle
Harness near the exhaust chafed or heat-damaged

Symptoms

  • Check engine light
  • Slower engine warm-up and weaker cabin heating in cold weather
  • Engine of the hybrid runs longer before it may shut off

Repair estimate

DifficultyHardWorkshop job
Parts and labour€150–1,500
Time1–4 h

Typical range across vehicles; the real cost depends on what the testing finds.

Parts involved

exhaust heat exchanger bypass valve a pos sensorwiring harnessecm

Related codes

P2C23P2C24P2C25P237CP237FP25D6

References: static.nhtsa.gov, static.nhtsa.gov, static.nhtsa.gov, patents.google.com.