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View Full Version : Check engine light/OBDII code P0402


Krytin
10-19-2009, 08:20 AM
"Excessive EGR flow".

The EGR valve itself is clean and moving smothly with no leak in the diaphram. All ports and passages are clear.

After considerable research this condition appears to be caused by a defective Differential Pressure Feedback EGR sensor or DPFE sensor.

My problem is this:
Part #'s for DPFE's can be found up until the 2002 model year for the 4.6 V8.
After that there is no listing for a seperate DPFE. There is also a significant increase in the price of the EGR valve itself starting in 2003.
It should also be noted that the DPFE and the vacuumm control solenoid appear to be an integral part of the EGR valve on my '03 MM.

The question then is - Did Ford, in their infinite wisdom, make one larger and more expensive part out of two or three smaller parts requiring the mass parts change for one component's failure?

This is actually on my '04 CV LX Sport out in San Diego. The car runs fine but the light keeps coming on. I'm flying out this weekend to visit and would like to fix this while I'm there.
Blackened300a
10-19-2009, 09:52 AM
I thought you were talking about the Marauder. I was gonna say, maybe shooting a 10ft flame out the exhaust might have been a reason. :D
Krytin
10-19-2009, 09:59 AM
I think that would only have been a problem if I tried to recirculate it!! LOL
Jason White
10-19-2009, 10:21 AM
The DPFE sensor is integrated in the EGR valve. You will need to replace EGR valve assy with integrated sensor.
Krytin
10-19-2009, 11:06 AM
The DPFE sensor is integrated in the EGR valve. You will need to replace EGR valve assy with integrated sensor.
That's what everything appeared to be pointing to, I just needed someone to confirm it.
Thank You Sir!!
RF Overlord
10-19-2009, 02:56 PM
^^^what Jason White said^^^
ImpalaSlayer
10-19-2009, 05:08 PM
hmmm then what is the the thing mounted on the firewall with 2 vac lines and a 6 pin plug going to it?
SpartaPerformance
10-19-2009, 05:56 PM
Paul PM me your email I can send you some pinpoint tests from AllData
Jason White
10-19-2009, 07:05 PM
The EGR valves are a very common part to fail on late model Fords. You will either get a P0401, or P0402. Of course without testing it is only an educated guess, but I replace them regularly at work on Explorers with the integrated sensor. The old style systems with the remote DPFE sensor have issues with water from exhaust shorting sensor internally which will give the same codes and can also generate a P14xx code. The DPFE sensor reads exhaust and voltage readings fluctuate with EGR operation. Normal voltage for a good DPFE sensor is .9-1.0 volts, when vacuum is applied to EGR valve it will go up to 2.xx volts.
Krytin
10-20-2009, 06:28 AM
hmmm then what is the the thing mounted on the firewall with 2 vac lines and a 6 pin plug going to it?
Vacuum Control Solenoid?
Krytin
10-20-2009, 06:44 AM
Paul PM me your email I can send you some pinpoint tests from AllData

PM's sent!
It helps when I put the email addy in - Doh!
Krytin
10-20-2009, 06:50 AM
The EGR valves are a very common part to fail on late model Fords. You will either get a P0401, or P0402. Of course without testing it is only an educated guess, but I replace them regularly at work on Explorers with the integrated sensor. The old style systems with the remote DPFE sensor have issues with water from exhaust shorting sensor internally which will give the same codes and can also generate a P14xx code. The DPFE sensor reads exhaust and voltage readings fluctuate with EGR operation. Normal voltage for a good DPFE sensor is .9-1.0 volts, when vacuum is applied to EGR valve it will go up to 2.xx volts.

Thanks again Jason and welcome to the site! My brother lives down on the south side of Huston over towards Galveston - what dealer ship do you work at? I'll send him over for the service on his F-150!
Jason White
10-20-2009, 08:38 AM
Ron Carter Ford in Alvin, TX