DTC P0402 [L3]

BME010200400W09

DTC P0402

EGR flow excessive detected

DETECTION CONDITION

• PCM monitors difference in intake manifold pressures when EGR is operated and when it is stopped. If the difference is too large, PCM determines that EGR flow excessive.
Diagnostic support note
• This is an intermittent monitor (EGR).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.

POSSIBLE CAUSE

• EGR valve gasket is not installed.
• EGR valve gasket has been damaged.
• PCM malfunction

Diagnostic procedure

STEP

INSPECTION

ACTION

1
VERIFY FREEZE FRAME DATA HAS BEEN RECORDED
• Has FREEZE FRAME DATA been recorded?
Yes
Go to next step.
No
Record FREEZE FRAME DATA on repair order, then go to next step.
2
VERIFY RELATED SERVICE INFORMATION AVAILABILITY
• Check for related Service Information availability.
• Is any related Service Information available?
Yes
Perform repair or diagnosis according to available Service Information.
• If vehicle is not repaired, go to next step.
No
Go to next step.
3
INSPECT FOR OTHER DTCS
• Turn the ignition switch off then to the ON position (Engine off).
• Have other DTCs been stored?
Yes
Repair circuit malfunction for applicable DTCs.
No
Go to next step.
4
INSPECT EGR VALVE GASKET HAS INSTALLED
• Turn the ignition switch off.
• Remove EGR valve.
• Is EGR valve gasket installed?
Yes
Go to next step.
No
Install EGR valve gasket, then go to Step 6.
5
INSPECT EGR VALVE GASKET MALFUNCTION
• Does EGR valve gasket have any crack and/or damage?
Yes
Replace EGR valve gasket, then go to Step 6.
No
Go to next step.
6
MONITOR EGR SYSTEM
• Clear DTC from PCM memory using WDS or equivalent.
• Start the engine and warm it up completely.
• Run the engine 2,800- 3,000 rpm with no load for 30 s.
• Idle the engine for 30 s.
• Access RFC FLAG PID using WDS or equivalent.
• Is RFC FLAG PID OFF?
Yes
Retry this step.
No
Go to next step.
7
VERIFY TROUBLESHOOTING OF DTC P0402 COMPLETED
• Make sure to reconnect all disconnected connectors.
• Drive the vehicle at 60- 75km/h {38- 46 mph} in 2nd gear for 30 s.
Yes
Go to next step.
No
Replace PCM, then go to next step.
8
VERIFY AFTER REPAIR PROCEDURE
• Perform "After Repair Procedure".
• Is there any DTC present?
Yes
Go to applicable DTC inspection.
No
Troubleshooting completed.