GM/Detroit 6.5L ENGINE CONTROLS – DTC P0402 Exhaust Gas Recirculation (EGR) Flow Excessive

Circuit Description
The mass air flow (MAF) sensor measures the amount of air entering the engine during a given time. The PCM uses the mass air flow information to monitor EGR flow rates. A large quantity of air entering the engine indicates an acceleration, high load situation or no EGR flow, while a small quantity of air indicates deceleration, idle or full EGR situations. The PCM will monitor MAF and EGR pressures at different ranges to determine correct EGR flow rates.

Conditions for Running the DTC
• The PCM performs this DTC diagnostic continuously.
• Baro greater than 75 kPa.
• The DTCs P0405, P0406, P0102 and P0103 are not set.

Conditions for Setting the DTC
• Five ALM Cells that are less than 0.5.
• All diagnostic set conditions met for 2 seconds.

Action Taken When the DTC Sets
• The PCM will shut down the EGR.
• The PCM illuminates the malfunction indicator lamp (MIL) on the second consecutive drive trip that the diagnostic runs and fails.
• The PCM records the operating conditions at the time the diagnostic fails. The first time the diagnostic fails, the Failure Records will store this information. If the diagnostic reports a failure on the second consecutive drive trip, the Freeze Frame records the operating conditions at the time of failure and updates the Failure Records.

Conditions for Clearing the MIL/DTC
• The PCM w ill turn the MIL off after three consecutive trips without a fault condition.
• A History DTC clears after forty consecutive warm-up cycles, if this or any other emission related diagnostic does not report any failures
• The use of a scan tool.

Diagnostic Aids
The most likely cause of failure is a mechanical problem in the EGR valve not allowing it to close. To run the diagnostic test the engine must be at operating temperature, with the vehicle in drive at idle for approximately 1 minute. Then, with the vehicle in park, hold engine rpm steady between 1500 and 2100 rpm for 30 seconds. If the diagnostic test fails to run, vehicle must be driven.

The Adaptive Learn Matrix (ALM) is used to adjust the EGR vacuum control based on mass air flow (MAF). The ALM may change as a result of back pressure increases over the life of the vehicle or other engine system variations. The ALM is made up of sixteen cells (numbered from zero to fifteen) in which each cell covers a range of engine speed (RPM) and load (mmS).

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Table.
3. If the EGR valve is at fault, excessive black smoke will be present.

 

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