P040200 Service Bulletin/Repair Instructions

DTC:
P0402-00
GDC18-058
Bulletin:
August 10, 2018
Date:

Description:

Applies to:
Engine Exhaust Gas Recirculation 1 Valve Position

Flow Excessive Detected

US13 - US Emissions
For Spanish click here: ESPAÑOL

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

x

x

x

x

x
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
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.

3. Raise hood. Note: Some models may be equipped with fender extenders attached to the inner splash

guard. Remove these as an assembly.
© 2016 Mack Trucks, Inc. Information is subject to change without notice.
Page 1/4
DTC:
P0402-00
Bulletin:

Date:
GDC18-058

August 10, 2018
4. 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
5. 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:

x Pin 1 — Green/White

x Pin 2 — Brown

x Pin 4 — White/Brown
© 2016 Mack Trucks, Inc. Information is subject to change without notice.
Page 2/4
DTC:
P0402-00
Bulletin:

Date:
GDC18-058

August 10, 2018
Note: The new engine harness connector pin locations when replacing old style EGR differential pressure sensor

with the new style sensor in kit are:

x Pin 1 — Green/White

x Pin 2 — Brown/White

x 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.
© 2016 Mack Trucks, Inc. Information is subject to change without notice.
Page 3/4
DTC:
P0402-00
Bulletin:

Date:
GDC18-058

August 10, 2018
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.

9. If applicable, install the inner splash guard assembly.

10. Close the hood.
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 – 0.6 (Depending on model)
Causal Part
22181342
© 2016 Mack Trucks, Inc. Information is subject to change without notice.
Page 4/4
DTC:
P0402-00
Boletín:

Fecha:
Descripción:

Se aplica a:
GDC18-032

20 de febrero de 2020
Exceso de flujo detectado en posición de válvula 1

de recirculación de gas de escape del motor

Emisiones de US13 - US
Para inglés, haga clic aquí: ENGLISH
Información general

Estas instrucciones de reparación están destinadas a abordar las siguientes fallas:

DTC
Descripción
P0402-00
Presión de diferencial

de recirculación de gas

de escape del motor Sistema mecánico

no responde

adecuadamente
Posibles síntomas

(observados)
Causa posible

x

x

x

x

x
Conector

Arnés de cableado

Válvula EGR

Fuga en el sistema de aire de carga

Sensor de la presión diferencial

de EGR
Flujo de masa de

EGR sobre el valor

calculado
Piezas necesarias
Número de pieza
Descripción
Cantidad
22181342
Sensor de presión diferencial de EGR
1
9812483
Herramienta de extractor
1
Instrucciones de reparación

Sensor de presión diferencial de EGR, Reemplazo
Desinstalación
1. Asegure el vehículo al estacionarlo en una superficie plana, aplicar el freno de estacionamiento, bloquear

la rueda trasera y poner la transmisión en neutro.

2. Desconecte todos los cables de los terminales positivos y negativos (tierra) de la batería para evitar

lesiones por descargas eléctricas y daños en los componentes eléctricos.

3. Levante el toldo. Nota: Algunos modelos pueden estar equipados con extensores de guardabarro a

la protección interna contra salpicaduras. Retírelas como un conjunto.
© 2016 Mack Trucks, Inc. La información está sujeta a cambios sin aviso previo.
Página 1/4
DTC:
P0402-00
Boletín:

Fecha:
GDC18-032

20 de febrero de 2020
4. Desconecte el terminal del arnés de cableado desde el terminal del conector en el sensor de presión

diferencial EGR. Afloje y retire los tornillos de montaje y retire el sensor de presión diferencial EGR

desde el tubo venturi. Nota: Instale los nuevos anillos de sellado cuando reemplace el sensor.
Sensor de presión

diferencial de EGR de
Sensor de presión

diferencial de EGR de
5. Limpie la superficie de sellado donde el sensor de presión diferencial de EGR se monta en el tubo venturi

EGR. Asegure que los puertos del tubo venturi estén totalmente abiertos y sin residuos.

Nota: Si los puertos al sensor de presión diferencial de EGR están obstruidos, revise el sistema EGR

completo en busca de obstrucciones y residuos. Limpie el sistema, según sea necesario.
Instalación
Nota: Si reemplaza un sensor de presión diferencial de EGR de estilo antiguo con un sensor de estilo nuevo,

realice los Pasos de instalación 1 a 3. Si reemplaza un sensor de presión diferencial de EGR de estilo nuevo

con un sensor de estilo nuevo, sale al Paso de instalación 4.

Nota: Cuando instale el kit para el sensor de presión diferencial de EGR actualizado en el motor D13, las clavijas

del conector del arnés del motor deben ser reubicadas. Las ubicaciones anteriores de las clavijas eran:

x Clavija 1 — Verde/Blanco

x Clavija 2 — Café

x Clavija 4 — Blanco/Café
© 2016 Mack Trucks, Inc. La información está sujeta a cambios sin aviso previo.
Página 2/4
DTC:
P0402-00
Boletín:

Fecha:
GDC18-032

20 de febrero de 2020
Nota: Las nuevas ubicaciones de las clavijas del conector del arnés del motor cuando reemplazan el sensor de

presión diferencial de EGR de estilo antiguo con el sensor de nuevo estilo en el kit son:

x Clavija 1 — Verde/Blanco

x Clavija 2 — Café/Blanco

x Clavija 3 — Café
1. Corte las amarras aplicables y retire las abrazaderas en P que aseguran la pata del arnés del sensor de

presión diferencial de EGR.

2. Utilice la herramienta de extractor (número de pieza 9812483) en kit 88890037 para reubicar las clavijas

del conector del arnés del motor. Herramientas especiales: 9812483

3. Conecte el arnés de puente del sensor de presión diferencial de EGR al arnés del motor.
4. Instale el sensor de presión diferencial de EGR.

5. Instale los sujetadores del sensor de presión diferencial de EGR. Apriete los sujetadores de acuerdo a

las especificaciones. Consulte Grupo de funciones 20, Especificaciones.
© 2016 Mack Trucks, Inc. La información está sujeta a cambios sin aviso previo.
Página 3/4
DTC:
P0402-00
Boletín:

Fecha:
GDC18-032

20 de febrero de 2020
6. Conecte el arnés del sensor de presión diferencial de EGR.

7. Instale todos los cables retirados anteriormente a los terminales negativos (tierra) de la batería.

8. Debido a la capacidad de autoaprendizaje del módulo de control electrónico (ECM), es necesario

restablecer los parámetros aprendidos de ECM después de reparar algunos componentes relacionados

con el motor. Esto permite que la ECM aprenda la nueva conducta de los componentes. Después de

terminar la reparación, realice el “Restablecimiento de datos aprendidos” usando Tech Tool. Esta se

encuentra en el menú del Grupo 1 de funciones.

9. Si es aplicable, instale el conjunto de protección interna contra salpicaduras.

10. Cierre el capó.
Recursos adicionales

Es muy probable que estas reparaciones solucionen la falla identificada; si esto no soluciona el problema, se

requerirá el uso de Tech Tool para diagnósticos más detallados. Si presenta una reclamación de garantía,

incluya el número de caso ASIST.

Código de trabajo

2939-03-02-01
0.5 – 0.6 (según la configuración)
Pieza causal
22181342
© 2016 Mack Trucks, Inc. La información está sujeta a cambios sin aviso previo.
Página 4/4

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