EGR (Exhaust Gas Recirculation) Solenoid Valve>P0402 EGR Flow Excessive Detected>Inspection/Repair>Component Inspection

Component Inspection

With exhaust gas recirculation (EGR) a portion of the exhaust gas is led into the engines intake tract. Up to
a certain degree, an increasing portion of the residual exhaust gas content has a positive effect upon
energy conversion and therefore upon the exhaust-gas emissions. Depending upon the engine operating
point, the air/gas mass drawn into the cylinders can be composed of up to 40% exhaust gas. For ECM
control, the actual drawn-in fresh-air mass is measured and compared at each operating point with the airmass setpoint. Using the signal generated by the control circuit, the EGR valve opens so that exhaust gas
can flow into the intake tract. EGR does not take place if the following conditions are met :
AFS signal failure
Fuel regulator valve and pressure sensor failure
Battery voltage is below 8.99 V
Water coolant temp. is below 37(98.6 ) or above 100(212 )
Starting
Fuel injection is above 45 cc
Engine over 3050 RPM
Less than 650 RPM
Atomospheric pressure (high altitiude)
- Lower 920 mbar : OFF
- Over 930 mbar : ON
How to Check the EGR Valve

1/3

EGR (Exhaust Gas Recirculation) Solenoid Valve>P0402 EGR Flow Excessive Detected>Inspection/Repair>Component Inspection

BASIC INSPECTION
Before performing the inspection of EGR sol. valve, make sure that the follwing items :
Incorrect installation position and loose for the vacuum hose ( Vaccum Out for EGR valve)
Check for leakage, breakage, clogging in vacuum hose to the EGR valve and solenoid valve
Pull off the vacuum hose from the EGR sol. valve and check for the vacuum from the alternator.
Check the mounting direction of MAF sensor and for the leakage of the intake system
CHECK PROCEDURE
1. The vaccum pressure of EGR sol. valve from the alternator
A. Test condition :
Keep the engine at 1500 rpm for more than 20 seconds and then conduct the measure as it is
B. Specification : Above 650 mmHg

Check the diaphram condition of EGR valve with the vacuum pump
- Replace the EGR valve If the EGR valve does not move upward and downward normally.
Inspect the EGR valve sticking and lift if the EGR valve stick is closed position or DTC PO402 occurs,
then black smoke arises. In this case, air flow sensor values goes down as against normal value at the
idle condtion
- Clean the alien material of passage inside the EGR valve with the cleaner
- Replace the EGR valve
- Clean the intake manifold EGR port with the cleaner.

How to Check the EGR Valve

1. Throttle solenoid valve

Disconnect the EGR sol. valve

2/3

EGR (Exhaust Gas Recirculation) Solenoid Valve>P0402 EGR Flow Excessive Detected>Inspection/Repair>Component Inspection
Disconnect the EGR sol. valve

Connect the ohmmeter probes to the EGR sol. valve terminal 1 and the terminal 2, measure the
resistance
A. Specification : 14 ~ 17 at 20(68 )

There are the "click" when the power is connected to the terminal 2 and the ground are connected to
the terminal 1.

2. Atmosphere port filter of EGR sol. valve

if the atmosphere port filter is clogged at the idle condition, the engine runs rough idle with the black
smoke. In this case, air flow sensor values goes down as against normal value at the idle condtion
- Clean the alien material of passage inside the EGR valve with the carburetor cleaner
- Clean the intake manifold EGR port with carburetor cleaner.

3/3