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[Engine] EGR 1.6 hdi - P0402 - case study
Here is small case study about dreadful P0402 error.

As I was pulling to the A1 went into limp mode. After 2 km stopped at the gas station and plugged in my
bluetooth OBDII android. Greeted with P0402 . Cleared the error and continued my journey. After another 2km
limp mode again. Same error. After 2 more stops and clearing the error find out that if I keep revs above 3000 rpm
I can continue without limp mode. If my revs fall to 2800 rpm i got limp mode. OK so I kept revs above 3k and continued
to the destination and back next day. Total 1000 km with revs above 3000 rpm.
Here is the OBDII error code:     

From OBDII error it is not clear if the ERG or MAF is causing the P0402. Dirty MAF can measure wrong air quantity
and trow P0402.

Connected the car to the Lexia and took a closer look at the error P0402 :     

Looking at the EGR valve position 89% and revs 2377 rpm it was no brainier. EGR was stuck open and it was 
passing more air into the engine than MAF sensor was picking up.

Time to take EGR apart.
This is electrical EGR. Consists of 2 parts. Lower mechanical part where the valve is situated and upper electrical motor part
witch is used to open and close regulating valve.     
Just undo 3 bolts and 2 parts are separated. When I moved lower part of the EGR it was moving freely.
When I moved upper electrical part there was some resistance. Like it was "jumping" in one place.
So I opened electrical part:     

I have found the problem. Bearing has lost it's lubricant due to carbon residue going to it. Without the proper lubricant bearing
balls were "eaten" at one point creating "jump". So the only solution is to order another EGR because it is impossible to change
that bearing. Mechanical part was ok and it was used to "blank" the EGR :     
With 2 wires connected to valve small shaft , valve is pulled up closing the gap and EGR is blocked properly.

I have ordered one from Aliexpress  90$ with shipping , 1 year warranty. Prices at the dealer are nightmare

After 3 weeks of driving with blanked EGR and limp mode fitted new EGR and cleared the error P0402 everything is OK. 

Sorry for the long post. Hope it helps someone.

Best regards,
[+] 5 users say Thank You to brajomobil for this post
Wow, many thanks brajomobil for the great, detailed post. I'm sure that will help some folks.
2010 Berlingo Multispace HDi 110 with FAP. Persamos green.

[Image: ab197646.gif]
[+] 1 user says Thank You to 3rensho for this post
Very helpful.Can it go into tutorials?
Strawberry flavoured windows  Dodgy
[+] 1 user says Thank You to ron for this post
Good one top mark's  Cool
                                     Smile  It's too orangey for crow's It's just for me and my dog  Smile

                                                        Heart Heart Love a lot trust a few  Dodgy

[+] 1 user says Thank You to Jed Clampit for this post
Thank you all for great feedback Smile

I am also preparing one tut for cheap oscilloscope arduino car diagnostic.

Best regards,
Quote:I am also preparing one tut for cheap oscilloscope arduino car diagnostic.

Looking forward to that.  I will have to dust off my arduino.
2010 Berlingo Multispace HDi 110 with FAP. Persamos green.

[Image: ab197646.gif]

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