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Questions and Answers

Ford Explorer Code P0402

Q. Hi Vince, I wrote one time before, but I'm still having the same problem: My 1996 Ford Explorer XLT V-8 with 113,000 miles is coding P0402 (excessive EGR flow at idle). It's been like that for two years. Now I want to repair. I found a cracked vacuum line from EGR vacuum solenoid to EGR and replaced it.

Ford Explorer Code P0402

I also replaced the EGR vacuum solenoid itself and EGR position sensor. EGR is holding vacuum and engine bogs down when I manually activate it, telling me EGR is not the problem. I don't think my model has a PFE manifold pressure sensor, just the position sensor that sits on top of the EGR.

I have cleared codes by battery disconnect and by computer, but light still comes on after 2 drive cycles. I would inspect or replace EGR valve itself if I could get it off. Mine is located on the back of the intake (next to firewall). The lower mounting bolt is tucked back in a little hollow underneath the valve, impossible to get to!

Any experience in changing EGR?
Any more ideas about the pesky light? (I suspect I need to get the EGR itself off and inspect, clean or replace). Here is original post:
Ford Explorer P0401 And P0402

Thanks,
Laine

A. You know, I was just looking at that Q&A not 20 minutes ago because someone with a 1999 Ford Ranger had the same problem. P0402 is "EGR FLow Excessive Detected".

It's possible the EGR valve itself is not closing completely. It's a little bit of work, but not too difficult to remove. Taking it out and doing a clean and inspection would be the best thing to do at this point.

REMOVAL:
  1. Disconnect the vacuum hose from the Exhaust Gas Recirculation (EGR) valve.
  2. Disconnect the electrical connector from the EGR valve sensor.
  3. Remove the EGR valve nuts and the EGR valve.
  4. Remove the EGR valve gasket and clean EGR gasket sealing surfaces.
INSTALLATION:
  • Position EGR valve with a new EGR valve gasket and install EGR valve nuts. Tighten to 15-22 lb ft.
  • Connect the electrical connector to the EGR valve sensor.
  • Connect the vacuum hose to the EGR valve.

Ford Explorer Code P0402
EGR Valve - Explorer 5.0
Located at intake manifold

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