DTC P0402:00 [PCM (SKYACTIV-D 2.2)]

System malfunction location	EGR control system: Excess EGR inducted
Detection condition	Determination condition	• The EGR volume is more than 0.3 g/rev of the target value for a continuous 8.2 s.
	Preconditions	• During EGR control • Engine speed:1,300 to 6,000 rpm • Fuel injection amount: 15 to 50 mm³/st • Engine torque: 80 to 240 Nm • The following DTCs are not detected ― MAP sensor No.2: P0106:00, P0107:00, P0108:00 ― BARO sensor: P2228:00, P2229:00 ― MAF sensor: P0102:00, P0103:00 ― EGR valve position sensor: P0405:00, P0406:00 ― EGR valve DC motor control system: P0404:00 ― EGR cooler bypass valve position sensor: P2494:00, P2495:00 ― EGR cooler bypass valve control system: P245A:00, P245B:00 ― EGR valve control system: P0488:00 ― Intake shutter valve position sensor: P0122:00, P0123:00 ― Intake shutter valve control system: P1589:00, P2101:00, P2118:00 ― IAT sensor No.2: P1118:00, P1119:00, P1147:00 ― Exhaust gas pressure sensor No.1: P0471:00, P0472:00, P0473:00 ― Exhaust gas temperature sensor No.1: P0545:00, P0546:00 ― Constant voltage power supply control system: P0642:00, P0643:00, P0652:00, P0653:00 ― MAP sensor No.2/BARO sensor: P0105:00 ― Exhaust gas pressure sensor No.1: P0470:00
	Drive cycle	• 1
	Self-test type	• CMDTC self test
	Sensor/unit used	• EGR valve • EGR cooler bypass valve • Intake shutter valve • MAF sensor • MAP sensor No.2 • Boost air temperature sensor • Exhaust gas pressure sensor No.1 • Exhaust gas temperature sensor No.1
Fail-safe	• Limits engine torque./ Limits the maximum engine speed. • Inhibits the automatic diesel particulate filter regeneration control. • Inhibits the manual diesel particulate filter regeneration control. • Inhibits the EGR control. • Inhibits engine-stop by i-stop control.
Vehicle status when DTCs are output	• Check engine light turns on
Possible cause	• PCM input signal error ― MAF sensor ― MAP sensor No.2 ― Boost air temperature sensor ― Exhaust gas pressure sensor No.1 ― Exhaust gas temperature sensor No.1 ― Input signal part connector or terminal malfunction ― Input signal part-related wiring harness malfunction • Intake shutter valve malfunction • EGR valve malfunction (stuck open) • EGR cooler bypass valve malfunction (stuck open) • Air suction from intake-air system piping (between turbocharger and intake manifold) • Restriction in EGR system piping • PCM malfunction

• The PCM performs diagnosis of the EGR system by comparing the target EGR volume with the actual.

• The PCM monitors the flow volume during EGR implementation.

• The PCM calculates the difference between the target EGR flow volume and the actual EGR flow volume during EGR implementation. If the monitored, actual flow volume is higher than the specification for the target flow volume, the PCM determines that there is inadequate flow volume.

• The PCM performs diagnosis when each of the preconditions during drive cycle is met. If a malfunction is detected, the malfunction detection counter begins counting up. If it is normal, the counter begins counting down.

The value of the malfunction detection counter is maintained while the preconditions are not being met. If the cumulative value of the malfunction detection counter exceeds the threshold during the first drive cycle, a malfunction is determined and a pending code is stored.

• If the PCM determines that the malfunction recurs from the next drive cycle and thereafter, it stores a DTC and turns on the check engine light.

1. Start the engine and warm it up.

2. Drive the vehicle at the constant speed of 70 km/h or morefor 1 min.

3. Repeat Step 2 two times or more.

Item name	Outline	Unit	Display/condition
EXHPRES1	Exhaust gas pressure (No.1)	kPa	• Idle: Approx. 100 kPa • Racing (engine speed 4,000 rpm): Approx. 193 kPa • Racing (engine speed 5,000 rpm): Approx. 266 kPa
EXHTEMP1	Exhaust gas temperature (No.1)	°C	• Displays exhaust gas temperature (No.1)
CACT12	Boost air temperature	°C	• Displays boost air temperature
MAF	Intake air amount	g/sec	• Ignition switched ON: Approx. 1.0 g/sec • Idle: Approx. 5.4 g/sec • Racing (engine speed 2,000 rpm): Approx. 13.84 g/sec • Racing (engine speed 4,000 rpm): Approx. 85.13 g/sec
MAP	Intake air pressure (No.2)	kPa	• Displays intake air temperature (No.2)

Step	Inspection	Results	Action
1	PURPOSE: VERIFY DTC CAUSING FREEZE FRAME DATA • Is DTC P0402:00 causing the freeze frame data?	Yes	Go to the next step.
1		No	Inspect the DTC causing the freeze frame data.
2	PURPOSE: RECORD VEHICLE STATUS AT TIME OF DTC DETECTION 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.
3	PURPOSE: VERIFY OTHER RELATED DTCs • Switch the ignition OFF, and then switch it ON (engine off). • Display the DTCs using the M-MDS. • Has any DTC other than P0402:00 been stored?	Yes	Repair the malfunctioning location according to the applicable DTC troubleshooting.
3		No	Go to the next step.
4	PURPOSE: VERIFY RELATED SENSOR INPUT SIGNAL • Start the engine and warm it up. • Display the following PIDs using the M-MDS. ― EXHPRES1 ― EXHTEMP1 ― CACT12 ― MAF ― MAP • Are the monitoring values normal?	Yes	Go to Troubleshooting Diagnostic Procedure to perform the procedure from step 1.
4		No	Go to the next step.
5	PURPOSE: INSPECT WIRING HARNESSES AND CONNECTORS FOR RELATED-SENSOR • Display the following PIDs using the M-MDS. ― EXHPRES1 ― EXHTEMP1 ― CACT12 ― MAF ― MAP • When the PCM, MAF sensor, MAP sensor No.2, boost air temperature sensor, exhaust gas pressure sensor No.1, and exhaust gas temperature sensor No.1 connectors are shaken, does the PID value include a PID item which has changed?	Yes	Inspect the related wiring harnesses and connectors. • Repair or replace the malfunctioning location. Go to Troubleshooting Diagnostic Procedure to perform the procedure from step 6.
5		No	Go to Troubleshooting Diagnostic Procedure to perform the procedure from step 1.

Step	Inspection	Results	Action
1	PURPOSE: INSPECT INTAKE SHUTTER VALVE • Inspect the intake shutter valve. • Is the intake shutter valve normal?	Yes	Go to the next step.
1		No	Replace the intake shutter valve, then go to Step 6.
2	PURPOSE: VERIFY EGR CONTROL VALVE OPERATION CONDITION • Perform the EGR control inspection. • Is the EGR valve operation normal?	Yes	Go to the next step.
2		No	Repair or replace the malfunctioning location, then go to Step 6.
3	PURPOSE: VERIFY EGR COOLER BYPASS VALVE OPERATION CONDITION • Perform the EGR control inspection. • Is the EGR cooler bypass valve operation normal?	Yes	Go to the next step.
3		No	Repair or replace the malfunctioning location, then go to Step 6.
4	PURPOSE: INSPECT INTAKE AIR SYSTEM FOR AIR SUCTION • Visually inspect the following intake air system for looseness or damage. ― Turbocharger and intake manifold • Is the intake air system normal?	Yes	Go to the next step.
4		No	Repair or replace the malfunctioning location, then go to Step 6.
5	PURPOSE: INSPECT EGR PASSAGE FOR CLOGGING • Switch the ignition OFF. • Remove the EGR valve. • Is the gasket correctly installed? Visually inspect the EGR passage for clogging. • Is the EGR passage normal?	Yes	Go to the next step.
5		No	Repair or replace the malfunctioning location, then go to the next step.
6	PURPOSE: VERIFICATION OF VEHICLE REPAIR COMPLETION • Reconnect all disconnected connectors and hoses. • Refer to the [MEMORY CLEARING PROCEDURE] and clear the DTC. • Implement the repeatability verification procedure. • Display the DTCs using the M-MDS. • Is DTC P0402:00 displayed?	Yes	Repeat the inspection from Step 1. • If the malfunction recurs, replace the PCM, then go to the next step.
6		No	Go to the next step.
7	PURPOSE: VERIFY IF THERE IS ANY OTHER MALFUNCTION • Has any other DTC or pending code been stored?	Yes	Repair the malfunctioning location according to the applicable DTC troubleshooting.
7		No	DTC troubleshooting completed.