C3 P0402 EGR Excessive Flow
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C3 P0402 EGR Excessive Flow
The freeze-frame data of this returning permanent fault appears to contradict the error code or am I missing something (I usually am!).
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Re: C3 P0402 EGR Excessive Flow
Check the vacum hoses. has your EGR been nobbled?
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Re: C3 P0402 EGR Excessive Flow
If the Measured air flow is higher than the expected value then it looks like the EGR valve is jammed closed (would expect to see copy position faults in this case) or the EGR valve is blanked off.
What is the airflow readings when the engine is idling & fully warmed up ?
What is the airflow readings when the engine is idling & fully warmed up ?
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Re: C3 P0402 EGR Excessive Flow
There's far less data than my C5 provides but what I have seen so far is EGR valve OCR% (at 5%) and no sight of any copy signal.
Lexia also shows EGR throttle OCR% (0%) which I believe is not fitted to this engine.
I'll get more data on next run out.
Lexia also shows EGR throttle OCR% (0%) which I believe is not fitted to this engine.
I'll get more data on next run out.
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Re: C3 P0402 EGR Excessive Flow
Doesn't the EGR throttle refer to the butterfly valve just before the inlet manifold?
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Re: C3 P0402 EGR Excessive Flow
To be honest, I was more doubting what little sanity I have left but if "Excessive EGR Flow" in this case actually means "Insufficient EGR Flow" then I'm good!
Re: C3 P0402 EGR Excessive Flow
The airflow readings from the MAF are the ones im interested in, they are a good indicator of what the EGR is actually doing.
The OCR% readings are what the ECU wants it to do.
Thought it was an electric EGR valve on this engine so wont be any copy signal on it unless there are wires coming off the EGR valve itself, in this case it uses the MAF to know what the EGR valve is doing.
The OCR% readings are what the ECU wants it to do.
Thought it was an electric EGR valve on this engine so wont be any copy signal on it unless there are wires coming off the EGR valve itself, in this case it uses the MAF to know what the EGR valve is doing.
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Re: C3 P0402 EGR Excessive Flow
This is what I have for this fault Mike: As you already know, you have the Siemens Injection System. This fault info is as listed for this Engine under your C3 and not a generic description.
Notes:
(*) Consequence for the parameter measurements:
Fault Code | P0406 |
After sales description of the fault code | Exhaust gas recycling electric valve position copy signal: Copy voltage too high |
Main customer complaints likely | Switching on of the diagnostic warning light; Noise: Cold |
Back-up mode following returning of the faults | The engine ECU cuts the regulating of the EGR (*); Programming status of the exhaust gas recycling valve |
Conditions for returning of the fault | When the valve is controlled: The fault codes are returned immediately in the engine management ECU; The diagnostic warning light only comes on and switches off after 3 engine starting cycles (**) |
Suspect Areas / Faulty Components | Engine ECU 5V shared supply; Electrical harness; Exhaust gas recycling valve |
Appropriate Tools | Adaptor harnesses; Multimeter; Controlled Terminal Box (in manual mode) or Manual Terminal Box |
Engine Concerned | DV6, DV4 Bosch, DV4 Siemens, DW10B Siemens, DW10B Delphi, DW12B Bosch |
(*) Consequence for the parameter measurements:
- OCR controlling the electric EGR valve = 0 %
- Position repeat = 0 %
- Engine start
- Engine cut-off
- Wait for the instrument panel to switch off
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Re: C3 P0402 EGR Excessive Flow
I'll get you the fuel system setup in a second which may help identify what it and isn't on the vehicle...
Electrical Circuit
Fuel System
Air Circuit
Electrical Circuit
Component | Reference | Remarks |
Diesel Injection ECU | 1 | - |
Engine Speed Sensor | 2 | Tightening torque: 5 m.daN (min.) and 10 m.daN (max.) Black 3-way |
Position Sensor (A.A.C) | 3 | Adjust the airgap of the camshaft position sensor 1,2 mm Grey 3-way |
Engine Coolant Temperature Sensor | 4 | On the coolant outlet housing |
Vehicle Speed Sensor | 5 | - |
Atmospheric Pressure Sensor | 6 | Incorporated in the injection ECU |
Battery | 7 | 12 Volts |
Injection Double Relay | 8 | Integrated with the engine fusebox |
Diagnostic Warning Lamp | 9 | Incorporated in the instrument panel |
Centralised Diagnostic Socket | 10 | Passenger compartment interior |
Transponder | 11 | Transponder integrated with the BSI and engine ECU |
Consumption Information | 12 | Incorporated in the instrument panel |
Tachometer | 13 | Incorporated in the instrument panel |
Heating Warning Lamp | 14 | Incorporated in the instrument panel |
Pre-Post Heat Box | 15 | - |
Pre-Heater Plug | 16 | - |
Accelerator Pedal Sensor | 17 | - |
Fuel System
Component | Reference | Remarks |
Fuel | 18 | Diesel |
High Pressure Fuel Sensor | 19 | - |
Fuel Tank | 20 | Capacity = 45 litre Composition = Polyethylene |
Fuel Filter | 21 | - |
Low Pressure Regulator | 22 | Fixed to the high pressure fuel pump |
Fuel Cooler | 23 | - |
Fuel Heater | 24 | Integrated in the fuel filter cover |
High Pressure Fuel Pump | 25 | The high pressure fuel pump is driven by the timing belt |
Fuel High Pressure Common Injection Rail | 26 | - |
Diesel Injectors | 27 | Piezo-electric controlled diesel injectors |
High Pressure Fuel Regulator | 28 | Fixed to the high pressure fuel pump |
Air Circuit
Component | Reference | Make | Reference | Remarks |
Air Flow Meter | 29 | SIEMENS | 39071LS.F | - |
Air Cleaner | 30 | MECAPLAST | 50557LP.A | Incorporated into the inlet manifold |
Turbocharger | 31 | KKK | Type KP35 | - |
Exhaust Gas Recycling Valve (EGR) | 32 | SAGEM | Type 2580132-A | - |
Recycling Regulation Electrovalve (EGR) | 33 | - | - | - |
Exhaust System | 34 | - | - | - |
Vacuum Pump | 35 | - | - | - |
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Marc
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Re: C3 P0402 EGR Excessive Flow
Here's the EGR - doesn't seem to be electrically operated for this part (1628XV), but what about the electrovalve (number 33 on the diagram)?
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Marc
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Re: C3 P0402 EGR Excessive Flow
Following a 15 mile round trip the results are....
Air flow matched Referenced flow almost to the digit throughout all driving ranges while the EGR commanded OCR% value never deviated from a constant 5%.
Although I do not have P0406 registered, todays data does appear to show the ECU backup mode of cutting EGR regulation.
Guess I should have cleared the fault first?
Yes it does have the EGR regulation valve (33) fitted to the front left side of the engine with all connections in place.
Air flow matched Referenced flow almost to the digit throughout all driving ranges while the EGR commanded OCR% value never deviated from a constant 5%.
Although I do not have P0406 registered, todays data does appear to show the ECU backup mode of cutting EGR regulation.
Guess I should have cleared the fault first?
Yes it does have the EGR regulation valve (33) fitted to the front left side of the engine with all connections in place.
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Re: C3 P0402 EGR Excessive Flow
So is there sufficient vacuum being generated Mike?
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Marc
Marc
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Re: C3 P0402 EGR Excessive Flow
I really don't want to have to test it at this point if it's not necessary. Besides, if the ECU has cut regulation and as the live data shows a fixed OCR 5% then I would expect to find no vacuum supplied to the EGR valve anyway.
I think i shall just have to wallow in my ignorance and leave it closed.
I think i shall just have to wallow in my ignorance and leave it closed.
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