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DTC P0402:00 [PCM (SKYACTIV-X)]

id0102u9155200

Note

• To determine the malfunctioning part, proceed with the diagnostics from "Function Inspection Using M-MDS".

Details On DTCs

Description

EGR valve control system: Excessive amount of EGR

Detection condition

Determination conditions

•  A condition in which the EGR valve opening angle is more than 5% or more relative to the target value continues for 3 s.

Preconditions

•  Engine coolant temperature: 20 °C {68 °F} or more

•  Battery voltage: 8 V or more^*1

•  The following DTC is not detected:

―  EGR valve control system: P0403:00, P0405:00, P0406:00

^*1: Standard can be verified by displaying PIDs using M-MDS

Drive cycle

•  1

Self test type

•  CMDTC self test, KOER self test

Sensor used

•  EGR valve position sensor

Fail-safe function

•  Inhibits the EGR control.

Vehicle status when DTCs are output

•  Not applicable

Possible cause

•  EGR valve/EGR valve position sensor connector or terminals malfunction

•  PCM connector or terminals malfunction

•  EGR valve position sensor malfunction

•  EGR valve malfunction (valve stuck open)

•  PCM malfunction

System wiring diagram

•  Not applicable

Connector diagram

•  Not applicable

Description	EGR valve control system: Excessive amount of EGR
Detection condition	Determination conditions	• A condition in which the EGR valve opening angle is more than 5% or more relative to the target value continues for 3 s.
Preconditions	• Engine coolant temperature: 20 °C {68 °F} or more • Battery voltage: 8 V or more^1 • The following DTC is not detected: ― EGR valve control system: P0403:00, P0405:00, P0406:00 ^1: Standard can be verified by displaying PIDs using M-MDS
Drive cycle	• 1
Self test type	• CMDTC self test, KOER self test
Sensor used	• EGR valve position sensor
Fail-safe function	• Inhibits the EGR control.
Vehicle status when DTCs are output	• Not applicable
Possible cause	• EGR valve/EGR valve position sensor connector or terminals malfunction • PCM connector or terminals malfunction • EGR valve position sensor malfunction • EGR valve malfunction (valve stuck open) • PCM malfunction
System wiring diagram	• Not applicable
Connector diagram	• Not applicable

Function Explanation (DTC Detection Outline)

• The PCM performs EGR system diagnosis by comparing the target EGR value opening angle with the actual EGR valve opening angle detected by the EGR valve position sensor.

• If the condition in which the actual EGR valve opening angle is more than 5 % or more relative to the target value continues for 3 s, the PCM stores a DTC.

Repeatability Verification Procedure

1. Start the engine and idle it.

2. Display PID EGR_ACT and simulation item EGR_COMD.

3. Change the simulation item EGR_COMD between 0 % and 100 %.

4. Verify that the PID EGR_ACT monitor value conforms to the simulation item EGR_COMD.

PID Item/Simulation Item Used In Diagnosis

PID/DATA monitor item table

PIDs	Reference
EGR_ACT	(See PID/DATA MONITOR TABLE [PCM (SKYACTIV-X)].)

Simulation item table

Simulation items	Reference
EGR_COMD	(See SIMULATION TABLE [PCM (SKYACTIV-X)].)

Function Inspection Using M-MDS

Step

Inspection

Results

Action

1

PURPOSE: VERIFY RELATED REPAIR INFORMATION OR SERVICE INFORMATION AVAILABILITY

•  Verify related Service Bulletins, on-line repair information, or Service Information availability.

•  Is any related Information available?

Yes

Perform repair or diagnosis according to the available information.

•  If the vehicle is not repaired, go to the next step.

No

Go to the next step.

2

PURPOSE: RECORD VEHICLE STATUS WHEN DTC WAS DETECTED TO UTILIZE WITH REPEATABILITY VERIFICATION

•  Record the freeze frame data/snapshot data.

Note

•  Recording can be facilitated using the screen capture function of the PC.

—

Go to Troubleshooting Diagnostic Procedure to perform the procedure from Step 1.

3

PURPOSE: INSPECT FOR OTHER RELATED DTCs

•  Perform the DTC inspection for the PCM.
(See DTC INSPECTION.)

•  Are any DTCs displayed?

Yes

Repair the malfunctioning location according to the applicable DTC troubleshooting.

(See DTC TABLE [PCM (SKYACTIV-X)].)

Go to the next step.

No

Go to the next step.

4

PURPOSE: VERIFY CONFORMITY OF EGR VALVE

•  Start the engine and idle it.

•  Access the following PIDs and simulation item using the M-MDS:
(See PID/DATA MONITOR INSPECTION.)

PIDs

―  EGR_ACT

Simulation item

―  EGR_COMD

•  Perform the following:

―  Change the simulation item EGR_COMD between 0% and 100%.

―  Verify that the PID EGR_ACT monitor value conforms to the simulation item EGR_COMD.

•  Does the monitor value of the PID item EGR_ACT conform to the EGR_COMD monitor value?

Yes

Go to the next step.

No

Go to Troubleshooting Diagnostic Procedure to perform the procedure from Step 1.

5

PURPOSE: VERIFY CONNECTOR CONNECTIONS

•  Access the following PIDs using the M-MDS:
(See PID/DATA MONITOR INSPECTION.)

PCM

―  EGR_ACT

•  Does the PID value fluctuate when the following connectors are shaken?

―  EGR valve/EGR valve position sensor

―  PCM

Yes

Inspect the related wiring harness and connector.

•  Repair or replace the malfunctioning part.

Go to Troubleshooting Diagnostic Procedure to perform the repair completion verification.

No

Go to Troubleshooting Diagnostic Procedure to perform the procedure from Step 1.

Step	Inspection	Results	Action
1	PURPOSE: VERIFY RELATED REPAIR INFORMATION OR SERVICE INFORMATION AVAILABILITY • Verify related Service Bulletins, on-line repair information, or Service Information availability. • Is any related Information available?	Yes	Perform repair or diagnosis according to the available information. • If the vehicle is not repaired, go to the next step.
No	Go to the next step.
2	PURPOSE: RECORD VEHICLE STATUS WHEN DTC WAS DETECTED TO UTILIZE WITH REPEATABILITY VERIFICATION • Record the freeze frame data/snapshot data. Note • Recording can be facilitated using the screen capture function of the PC.	—	Go to Troubleshooting Diagnostic Procedure to perform the procedure from Step 1.
3	PURPOSE: INSPECT FOR OTHER RELATED DTCs • Perform the DTC inspection for the PCM. (See DTC INSPECTION.) • Are any DTCs displayed?	Yes	Repair the malfunctioning location according to the applicable DTC troubleshooting. (See DTC TABLE [PCM (SKYACTIV-X)].) Go to the next step.
No	Go to the next step.
4	PURPOSE: VERIFY CONFORMITY OF EGR VALVE • Start the engine and idle it. • Access the following PIDs and simulation item using the M-MDS: (See PID/DATA MONITOR INSPECTION.) PIDs ― EGR_ACT Simulation item ― EGR_COMD • Perform the following: ― Change the simulation item EGR_COMD between 0% and 100%. ― Verify that the PID EGR_ACT monitor value conforms to the simulation item EGR_COMD. • Does the monitor value of the PID item EGR_ACT conform to the EGR_COMD monitor value?	Yes	Go to the next step.
No	Go to Troubleshooting Diagnostic Procedure to perform the procedure from Step 1.
5	PURPOSE: VERIFY CONNECTOR CONNECTIONS • Access the following PIDs using the M-MDS: (See PID/DATA MONITOR INSPECTION.) PCM ― EGR_ACT • Does the PID value fluctuate when the following connectors are shaken? ― EGR valve/EGR valve position sensor ― PCM	Yes	Inspect the related wiring harness and connector. • Repair or replace the malfunctioning part. Go to Troubleshooting Diagnostic Procedure to perform the repair completion verification.
No	Go to Troubleshooting Diagnostic Procedure to perform the procedure from Step 1.

Troubleshooting Diagnostic Procedure

Intention of troubleshooting procedure

• Step 1

― Perform a unit inspection of the EGR valve.

• Repair completion verification

― Verify that the primary malfunction is resolved and there are no other malfunctions.

Step

Inspection

Results

Action

1

PURPOSE: INSPECT EGR VALVE FOR MALFUNCTION

•  Inspect the applicable part.
(See EGR VALVE INSPECTION [SKYACTIV-X 2.0].)

•  Is the part normal?

Yes

Go to the next step.

No

Repair or replace the malfunctioning location and perform the repair completion verification.

(See EGR VALVE REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

Repair completion verification 1

PURPOSE: VERIFY THAT VEHICLE IS REPAIRED

•  Install/connect the part removed/disconnected during the troubleshooting procedure.

•  Clear the DTC recorded in the memory.
(See CLEARING DTC.)

•  Replicate the vehicle conditions at the time the DTC was detected using the following procedure.

―  Implement the repeatability verification procedure.
(See Repeatability Verification Procedure.)

•  Perform the DTC inspection for the PCM.
(See DTC INSPECTION.)

•  Is the same Pending DTC present?

Yes

Refer to the controller area network (CAN) malfunction diagnosis flow to inspect for a CAN communication error.

(See CONTROLLER AREA NETWORK (CAN) MALFUNCTION DIAGNOSIS FLOW [(E)].)

If the CAN communication is normal, perform the diagnosis from Step 1.

•  If the malfunction recurs, replace the PCM, then go to the next step.
(See PCM REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)

No

Go to the next step.

Repair completion verification 2

PURPOSE: VERIFY IF OTHER DTCs DISPLAYED

•  Perform the DTC inspection.
(See DTC INSPECTION.)

•  Are any other DTCs displayed?

Yes

Repair the malfunctioning location according to the applicable DTC troubleshooting.

No

DTC troubleshooting completed.

Step	Inspection	Results	Action
1	PURPOSE: INSPECT EGR VALVE FOR MALFUNCTION • Inspect the applicable part. (See EGR VALVE INSPECTION [SKYACTIV-X 2.0].) • Is the part normal?	Yes	Go to the next step.
1		No	Repair or replace the malfunctioning location and perform the repair completion verification. (See EGR VALVE REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)
Repair completion verification 1	PURPOSE: VERIFY THAT VEHICLE IS REPAIRED • Install/connect the part removed/disconnected during the troubleshooting procedure. • Clear the DTC recorded in the memory. (See CLEARING DTC.) • Replicate the vehicle conditions at the time the DTC was detected using the following procedure. ― Implement the repeatability verification procedure. (See Repeatability Verification Procedure.) • Perform the DTC inspection for the PCM. (See DTC INSPECTION.) • Is the same Pending DTC present?	Yes	Refer to the controller area network (CAN) malfunction diagnosis flow to inspect for a CAN communication error. (See CONTROLLER AREA NETWORK (CAN) MALFUNCTION DIAGNOSIS FLOW [(E)].) If the CAN communication is normal, perform the diagnosis from Step 1. • If the malfunction recurs, replace the PCM, then go to the next step. (See PCM REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)
Repair completion verification 1		No	Go to the next step.
Repair completion verification 2	PURPOSE: VERIFY IF OTHER DTCs DISPLAYED • Perform the DTC inspection. (See DTC INSPECTION.) • Are any other DTCs displayed?	Yes	Repair the malfunctioning location according to the applicable DTC troubleshooting.
Repair completion verification 2		No	DTC troubleshooting completed.