P040200

DTC (Code)
Codigo:
Bulletin:
P0402 - 00
RD20-002
Date Fecha: August 03, 2020
Description:
Engine Exhaust Gas Recirculation Differential Pressure Mechanical system not responding properly
Application:
US13 – US20 Emissions
General Information
These repair instructions are intended to address the following fault(s)::
DTC
Description
P0402-00
Engine Exhaust Gas
Recirculation
Differential Pressure
- Mechanical system
not responding
properly
Possible Cause
•
•
•
•
•
Connector
Wiring harness
EGR Valve
Charge air system leakage
EGR differential pressure sensor
Possible (Observable)
Symptoms
EGR mass flow above
calculated value
Required Parts
Part Number
Description
Quantity
22181342 / 22172068
(Depending on model year)
EGR Differential Pressure
Sensor
1
9812483
Extractor Tool
1
Repair Instructions
EGR Differential Pressure Sensor, Replacement
Removal
1. Secure the vehicle for service by parking it on a flat level surface, applying the parking brake, chocking the
rear wheel, and placing the transmission in neutral.
2. Disconnect all cables from the negative (ground) and positive battery terminals to prevent personal injury
from electrical shock and prevent damage to electrical components.
© 2020 Information is subject to change without notice.
Page 1 of 4
DTC (Code)
Codigo:
P0402 - 00
Bulletin:
RD20-002
Date Fecha: August 03, 2020
3. Disconnect the wiring harness lead from the connector terminal on the EGR pressure differential sensor.
Loosen and remove the mounting bolts and remove the EGR pressure differential sensor from the venturi
tube. Note: Install new sealing rings when replacing the sensor.
Old Style EGR
Differential Pressure
New Style EGR
Differential Pressure
4. Clean the sealing surface where the EGR differential pressure sensor mounts into the EGR venturi tube.
Ensure that the ports of the venturi tube are fully open and free of debris. Note: If the ports to the EGR
differential pressure sensor are clogged check the entire EGR system for clogging and debris. Clean the
system as needed.
Installation
Note: If replacing an old style EGR differential pressure sensor with a new style sensor, perform Installation Steps 1
through 3. If replacing a new style EGR differential pressure sensor with a new style sensor, skip to Installation
Step 4.
Note: When installing the kit for the updated EGR differential pressure sensor for the D13 engine, the engine
harness connector pins will need to be relocated. The previous pin locations were:
• Pin 1 — Green/White
• Pin 2 — Brown
• Pin 4 — White/Brown
© 2020 Information is subject to change without notice.
Page 2 of 4
DTC (Code)
Codigo:
P0402 - 00
Bulletin:
RD20-002
Date Fecha: August 03, 2020
Note: The new engine harness connector pin locations when replacing old style EGR differential pressure sensor
with the new style sensor in kit are:
• Pin 1 — Green/White
• Pin 2 — Brown/White
• Pin 3 — Brown
1. Clip applicable cable ties and remove P-clamps securing the EGR differential pressure sensor harness leg.
2. Use extractor tool (part number 9812483) in kit 88890037 to relocate the engine harness connector pins.
Special tools: 9812483
3. Connect the EGR differential pressure sensor jumper harness to the engine harness.
4. Install the EGR differential pressure sensor.
5. Install the EGR differential pressure sensor fasteners. Tighten fasteners to specification. Refer to Function
Group 20, Specifications.
© 2020 Information is subject to change without notice.
Page 3 of 4
DTC (Code)
Codigo:
Bulletin:
P0402 - 00
RD20-002
Date Fecha: August 03, 2020
6. Connect the EGR differential pressure sensor harness.
7. Install all previously removed cables to the ground (negative) battery terminals.
8. Due to the electronic control module (ECM) self-learning capability, it is necessary to reset learned ECM
parameters after servicing some engine related components. This allows the ECM to learn the new
components behavior. After servicing is complete, perform the “Learned Data Reset” using Tech Tool. This
is located in the Function Group 1 menu.
Additional Resources
These repairs are the most likely fix for the identified fault, if this does not fix the issue, Tech Tool will need to be used
for more detailed diagnostics. If filing a warranty claim, please include the ASIST case number.
Labor Code
2939-03-02-01
0.4
Causal Part
22181342 / 22172068
© 2020 Information is subject to change without notice.
Page 4 of 4