P0420 on Your Ford Explorer - What's Wrong & What It Costs

2011-2023 Ford Explorer
P0420
Catalyst System Efficiency Below - Ford Explorer
On the 2011-2023 Ford Explorer, P0420 is most often caused by an aging ignition coil pack on cylinder 1 - a $50-$120 part that fails between 80k and 130k miles
Moderate-High Severity $80-$650 Repair Range DIY-Friendly
Plain English

What P0420 means for your Ford Explorer

Your Camry's ECM detected that cylinder 1 isn't firing properly - the crankshaft position sensor saw the rotational speed dip slightly each time cylinder 1 was supposed to combust. On the 2.5L 2AR-FE and earlier 2AZ-FE, this almost always traces back to a tired ignition coil. Toyota's coils are durable but they have a typical service life of 80k-130k miles, and once one starts to break down it usually shows up as P0420 (or P0302/P0303/P0304) under load. The cylinder-1 coil sits at the front of the engine and runs slightly hotter than the rear coils, which is why it tends to fail first.

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🎯 Top Causes on the Ford Explorer

40%
#1 MOST LIKELY
Cracked Exhaust Manifold (3.5L Cyclone)
3.5L Cyclone V6 Explorers (2011-2019) crack exhaust manifolds frequently. The leak introduces oxygen pre-cat, making the cat read as failing. Listen for cold-start tick.
PART

🎯 Top Causes on the Ford Explorer

50–$500
LABOR
00–$800
DIY
Hard
30%
#2 COMMON
Aged Downstream O2 Sensor
Bank 1 Sensor 2 wears at 100k+ on all engine variants. Test first before replacing the cat.
PART
$60–
60%
#1 CAUSE
Failing Cylinder 1 Ignition Coil
Toyota uses coil-on-plug (COP) ignition - one coil per cylinder bolted directly above the spark plug. After 80k-130k miles the secondary windings in the cylinder-1 coil break down and the spark gets weak under load. Easy diagnostic trick: swap the cylinder 1 coil with the cylinder 3 coil and clear the code. If the misfire moves to P0303, the coil is the problem. Denso and NGK make Toyota OEM-equivalent coils for around $50-$80 each. Replace all four coils as a set if mileage is high - they all age together.
OEM Coil
$80-$120
Aftermarket
$45-$70
w/Labor
$120-$280
25%
#2 CAUSE
Worn Spark Plug on Cylinder 1
The Camry's iridium plugs are spec'd for 100k miles but they wear early if oil consumption is present (especially on 2007-2009 2AZ-FE engines, which have a known oil-burning issue). A worn plug raises the firing voltage demand and overstresses the coil. Check the cylinder-1 plug for excessive gap, oil fouling, or a worn electrode. Use only Denso or NGK iridium plugs - cheap copper plugs cause repeat misfires within months on this engine.
Plugs (set 4)
$30-$60
V6 Plugs (6)
$45-$90
w/Labor
$80-$220
15%
#3 CAUSE
Fuel Injector Clog or Leak
If the cylinder-1 injector is partially clogged or leaking, the air-fuel ratio in that cylinder is wrong and you get a single-cylinder misfire that swaps when you swap injectors. Less common than coil/plug but worth checking after the easy stuff. Pull the injectors and have them flow-tested at a shop, or just replace the cylinder-1 injector with a known-good unit to confirm.
Injector
$60-$140
Flow Test
$80-$150
w/Labor
$150-$320
00
LABOR
$80–

🎯 Top Causes on the Ford Explorer

50
DIY
Easy
20%
#3 POSSIBLE
EcoBoost Carbon Buildup
Direct injection on 3.5L/2.3L EcoBoost engines builds carbon on intake valves at 60k-100k. Walnut blasting extends cat life.
PART
60%
#1 CAUSE
Failing Cylinder 1 Ignition Coil
Toyota uses coil-on-plug (COP) ignition - one coil per cylinder bolted directly above the spark plug. After 80k-130k miles the secondary windings in the cylinder-1 coil break down and the spark gets weak under load. Easy diagnostic trick: swap the cylinder 1 coil with the cylinder 3 coil and clear the code. If the misfire moves to P0303, the coil is the problem. Denso and NGK make Toyota OEM-equivalent coils for around $50-$80 each. Replace all four coils as a set if mileage is high - they all age together.
OEM Coil
$80-$120
Aftermarket
$45-$70
w/Labor
$120-$280
25%
#2 CAUSE
Worn Spark Plug on Cylinder 1
The Camry's iridium plugs are spec'd for 100k miles but they wear early if oil consumption is present (especially on 2007-2009 2AZ-FE engines, which have a known oil-burning issue). A worn plug raises the firing voltage demand and overstresses the coil. Check the cylinder-1 plug for excessive gap, oil fouling, or a worn electrode. Use only Denso or NGK iridium plugs - cheap copper plugs cause repeat misfires within months on this engine.
Plugs (set 4)
$30-$60
V6 Plugs (6)
$45-$90
w/Labor
$80-$220
15%
#3 CAUSE
Fuel Injector Clog or Leak
If the cylinder-1 injector is partially clogged or leaking, the air-fuel ratio in that cylinder is wrong and you get a single-cylinder misfire that swaps when you swap injectors. Less common than coil/plug but worth checking after the easy stuff. Pull the injectors and have them flow-tested at a shop, or just replace the cylinder-1 injector with a known-good unit to confirm.
Injector
$60-$140
Flow Test
$80-$150
w/Labor
$150-$320
00–$500
LABOR
$400–$800
DIY
Hard
10%
#4 POSSIBLE
Failed Catalytic Converter
Past 150k or with sustained misfires, the cat itself can fail. CARB-compliant aftermarket $500-

🎯 Top Causes on the Ford Explorer

,200.
PART
$500–

🎯 Top Causes on the Ford Explorer

,500
LABOR
00–$600
DIY
Medium

🚗 Most Affected Camry Model Years

YearEnginePrimary CauseTypical MileageNotes
2010-20172.5L 2AR-FECoil pack80k-130kMost common P0420 reports
2007-20092.4L 2AZ-FECoil + oil-fouled plug90k-160kOil consumption shortens plug life
2018+2.5L A25A-FKSCoil pack60k-90kNewer engine, fewer reports so far
2007-20173.5L 2GR-FE V6Rear-bank coils80k-130kRear coils harder to access

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