DTC P0402:00 [SKYACTIV-D 1.5]

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

Details On DTCs

DESCRIPTION

HP-EGR flow excessive detected
DETECTION CONDITION
Determination conditions
•  When the following condition is met, the HP-EGR volume is higher than the specification for the target value for a continuous specified time.
Preconditions
•  During HP-EGR control
•  Engine speed: 1,200—2,500 rpm
•  Fuel injection amount:4—50 mm3/stoke
•  Engine torque: 20—240 N·m {2.1—24 kgf·m, 15—177 ft·lbf}
•  The following DTCs are not detected:
―  MAP sensor: P0107:00, P0108:00
―  MAF sensor: P0102:00, P0103:00
―  Exhaust gas pressure sensor No.1: P0472:00, P0473:00
―  Exhaust gas temperature sensor No.1: P0546:00
―  Intake shutter valve control: P2101:00, P2118:00, P1589:00
―  Intake shutter valve position sensor: P0122:00, P0123:00
―  HP-EGR control valve DC motor control system: P0404:00, P0488:00
―  HP-EGR control valve position sensor: P0405:00, P0406:00
―  LP-EGR control valve DC motor control system: P045B:00, P213B:00
―  LP-EGR control valve position sensor: P0407:00, P0408:00
―  Exhaust shutter valve DC motor control system: P0475:00, P0476:00
―  Exhaust shutter valve position sensor: P048D:00, P048E:00
―  Internal PCM malfunction: P062B:00
―  Fuel injector: P0201:00, P0202:00, P0203:00, P0204:00, P02EE:00, P02EF:00, P02F0:00, P02F1:00, P1378:00, P1379:00, P2146:00, P2147:00, P2148:00, P2149:00, P2150:00, P2151:00
Drive cycle
•  1
Self test type
•  CMDTC self test
Sensor used
•  HP-EGR control valve
•  Intake shutter valve
•  LP-EGR control valve
•  Exhaust shutter valve
•  MAF sensor
•  MAP sensor
•  Boost air temperature sensor
•  Exhaust gas pressure sensor No.1
•  Exhaust gas temperature sensor No.1
FAIL-SAFE FUNCTION
•  PCM restricts engine torque.
•  Inhibits the EGR control.
•  Inhibits the auto diesel particulate filter regeneration control.
•  Inhibits the compulsory diesel particulate filter regeneration control.
•  Inhibits engine-stop by operating the i-stop function.
VEHICLE STATUS WHEN DTCs ARE OUTPUT
•  Check engine light is illuminated
POSSIBLE CAUSE
•  Erratic signal to PCM
―  MAF sensor signal malfunction
―  MAP sensor signal malfunction
―  Boost air temperature sensor signal malfunction
―  Exhaust gas pressure sensor No.1 signal malfunction
―  Exhaust gas temperature sensor No.1 signal malfunction
―  Input signal part connector or terminals malfunction
―  Input signal part related circuit malfunction
•  Intake shutter valve malfunction
•  HP-EGR control valve malfunction (stuck open)
•  Air suction in intake air system between turbocharger with variable turbine geometry and intake manifold
•  HP-EGR system passage malfunction (restriction)
•  PCM malfunction


System Wiring Diagram

•  Not applicable

Function Explanation (DTC Detection Outline)

•  The PCM performs diagnosis of the HP-EGR system by comparing the target EGR volume with the actual.
•  The PCM monitors the flow volume during HP-EGR implementation.
•  The PCM calculates the difference between the target EGR flow volume and the actual EGR flow volume during HP-EGR implementation. If the monitored, actual flow volume is higher than the specification for the target flow volume, the PCM determines that there is excessive 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. The value of the malfunction detection counter is maintained while the preconditions are not being met.
•  If the calculated value of the malfunction detection counter during one drive cycle exceeds the threshold, the PCM determines a malfunction, stores a DTC and turns on the check engine light.
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Repeatability Verification Procedure

Caution
•  When the M-MDS is used to observe monitor system status while driving, be sure to have another technician with you, or record the data in the M-MDS using the PID/DATA MONITOR AND RECORD capturing function and inspect later.
•  While performing this step, always operate the vehicle in a safe and lawful manner.
1.  Start the engine at the engine cold condition.
2.  Confirm that the low engine coolant temperature indicator light (blue) illuminates.
3.  Drive the vehicle for 1 min at a speed of 50 km/h {32 mph} or more.
4.  Repeat Step 3 operation above 2 times.

PID Item/Simulation Item Used In Diagnosis

PID/DATA monitor item table

Item

Definition

Unit

Condition/Specification
CACT11
Boost air temperature
°C, °F
•  Displays the boost air temperature
EXHPRES1
Exhaust gas pressure (No.1)
kPa, Bar, psi
•  Idle: Approx. 106 kPa {1.08 kgf/cm2, 15.4 psi}
•  Racing (engine speed above 2,000 rpm): Approx. 112 kPa {1.14 kgf/cm2, 16.2 psi}
•  Racing (engine speed above 4,000 rpm): Approx. 220 kPa {2.24 kgf/cm2, 31.9 psi}
EXHTEMP1
Exhaust gas temperature (No.1)
°C, °F
•  Displays the exhaust gas temperature (No.1)
MAF
Mass air flow
g/Sec
•  Switch ignition ON (engine off): Approx. 0.38 g/s {0.050 lb/min}
•  Idle: 2.2—4.5 g/s {0.30—0.59 lb/min}
•  Racing (engine speed 2,000 rpm): 8.0—9.5 g/s {1.1—1.2 lb/min}
•  Racing (engine speed 4,000 rpm): 50—56 g/s {6.7—7.4 lb/min}
MAP
Manifold absolute pressure input from MAP sensor
kPa, Bar, psi
•  Switch ignition ON (engine off): Approx. 100.37 kPa {1.0235 kgf/cm2, 14.557 psi}
•  Idle: Approx. 82 kPa {0.84 kgf/cm2, 12 psi}

Function Inspection Using M-MDS

STEP

INSPECTION

ACTION
1
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/snapshot data on the repair order.
—
Go to the next step.
2
PURPOSE: VERIFY RELATED SERVICE INFORMATION AVAILABILITY
•  Verify related Service Information availability.
•  Is any related Service Information available?
Yes
Perform repair or diagnosis according to the available Service Information.
•  If the vehicle is not repaired, go to the next step.
No
Go to the next step.
3
PURPOSE: IDENTIFY TRIGGER DTC FOR FREEZE FRAME DATA
•  Is the DTC P0402:00 on FREEZE FRAME DATA?
Yes
Go to the next step.
No
Go to the troubleshooting procedure for DTC on FREEZE FRAME DATA.
(See DTC TABLE [SKYACTIV-D 1.5].)
4
PURPOSE: VERIFY IF DIAGNOSTIC RESULT IS AFFECTED BY OTHER RELATED DTCs OCCURRING
•  Switch the ignition off, then ON (engine off).
•  Perform the Pending Trouble Code Access Procedure and DTC Reading Procedure.
•  Is the other PENDING CODE/DTC also present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [SKYACTIV-D 1.5].)
No
Go to the next step.
5
PURPOSE: VERIFY IF THERE IS PID ITEM CAUSING DRASTIC CHANGES OF ACCELERATION FLUCTUATION BY INPUT SIGNAL TO PCM
•  Access the following PIDs using the M-MDS:
PCM:
―  EXHPRES1
―  EXHTEMP1
―  CACT11
―  MAF
―  MAP
•  Is there any signal that is far out of specification?
Yes
Go to the next step.
No
Go to the troubleshooting procedure to perform the procedure from Step 1.
6
PURPOSE: VERIFY CONNECTOR CONNECTIONS
•  Access the following PIDs using the M-MDS:
PCM:
―  EXHPRES1
―  EXHTEMP1
―  CACT11
―  MAF
―  MAP
•  When the following parts are shaken, does the PID value include a PID item which has changed?
―  Exhaust gas pressure sensor No.1
―  Exhaust gas temperature sensor No.1
―  Charge air temperature sensor
―  MAF sensor
―  MAP sensor
―  PCM
Yes
Repair or replace the applicable connector parts.
Go to the troubleshooting procedure to perform the procedure from Step 5.
No
Go to the troubleshooting procedure to perform the procedure from Step 1.


Troubleshooting Diagnostic Procedure

Intention of troubleshooting procedure
•  Step 1—2
―  Perform inspection of each separate part.
•  Step 3—4
―  Perform inspection of HP-EGR control valve passage
•  Step 5—6
―  Verify that the primary malfunction is resolved and there are no other malfunctions.

STEP

INSPECTION

ACTION
1
PURPOSE: INSPECT INTAKE SHUTTER VALVE CONTROL SYSTEM OPERATION
•  Perform the Intake Shutter Valve Operation Inspection.
•  Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results, then go to Step 5.
No
Go to the next step.
2
PURPOSE: INSPECT HP-EGR CONTROL VALVE CONTROL SYSTEM OPERATION
•  Perform the HP-EGR Control Valve Operation Inspection.
•  Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results, then go to Step 5.
No
Go to the next step.
3
PURPOSE: INSPECT INTAKE AIR SYSTEM FOR AIR SUCTION
•  Inspect for air leakage at the following:
―  Around connection of turbocharger with variable turbine geometry and intake manifold
Note
•  Engine speed may change when rust penetrating agent is sprayed on the air suction area.
•  Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results, then go to Step 5.
No
Go to the next step.
4
PURPOSE: INSPECT FOR RESTRICTION OR CLOGGED IN HP-EGR PASSAGE
•  Switch the ignition off.
•  Remove the HP-EGR control valve.
•  Visually inspect the HP-EGR passage for clogging and the gasket correctly installed.
•  Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results, then go to the next step.
No
Go to the next step.
5
PURPOSE: PERFORM DTC INSPECTION AND VERIFY IF MALFUNCTIONING PART IS PCM
•  Always reconnect all disconnected connectors.
•  Clear the DTC from the PCM memory using the M-MDS.
•  Implement the repeatability verification procedure.
•  Perform the DTC Reading Procedure.
•  Is the same DTC present?
Yes
Repeat the inspection from Step 1.
•  If the malfunction recurs, replace the PCM.
Go to the next step.
No
Go to the next step.
6
PURPOSE: VERIFY AFTER REPAIR PROCEDURE
•  Perform the “AFTER REPAIR PROCEDURE”.
•  Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [SKYACTIV-D 1.5].)
No
DTC troubleshooting completed.