NHTSA ID Number: 10180430
Manufacturer Communication Number: P040200
TSB/Document Date: 2020-09-30
Summary
Engine Exhaust Gas Recirculation 1 Valve Position Flow Excessive Detected
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TSB/Document ID: P040200
Replacement Service Bulletin Number:
MFR Communication Date: 2020-09-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
MFR Component System:
MFR Component Subsystem:
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REMOTE DIAGNOSTICS - REPAIR INSTRUCTIONS
S
DTC:
P0402-00
Bulletin:
Date:
RD20-008
August 3, 2020
Engine Exhaust Gas Recirculation 1 Valve Position Flow
Excessive Detected
Description:
Applies to:
US13 – US20 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
•
•
•
•
•
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.
3. Raise hood. Note: Some models may be equipped with fender extenders attached to the inner splash
guard. Remove these as an assembly.
Page 1 of 4
© 2020 Volvo
Group North America, LLC. Information is subject to change without notice.
REMOTE DIAGNOSTICS - REPAIR INSTRUCTIONS
DTC:
S
P0402-00
Bulletin:
Date:
RD20-008
August 3, 2020
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:
• Pin 1 — Green/White
• Pin 2 — Brown
• Pin 4 — White/Brown
Page 2 of 4
© 2020 Volvo Group North America, LLC. Information is subject to change without notice.
REMOTE DIAGNOSTICS - REPAIR INSTRUCTIONS
DTC:
S
P0402-00
Bulletin:
Date:
RD20-008
August 3, 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.
Page 3 of 4
© 2020 Volvo Group North America, LLC. Information is subject to change without notice.
REMOTE DIAGNOSTICS - REPAIR INSTRUCTIONS
DTC:
S
P0402-00
Bulletin:
Date:
RD20-008
August 3, 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.
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
0.5 – 0.6 (Depending on configuration)
Causal Part
22181342 / 22172068
Page 4 of 4
© 2020 Volvo Group North America, LLC. Information is subject to change without notice.
INSTRUCCIONES DE REPARACIÓN DE DIAGNÓSTICO REMOTO
DTC:
Descripción:
Se aplica a:
P0402-00
Boletín: RD20-026
Fecha: 03 de agosto de 2020
Exceso de flujo detectado en posición de válvula 1 de
recirculación de gas de escape del motor
Emisiones de US13 – US20
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
Causa posible
•
•
•
•
•
Conector
Arnés de cableado
Válvula EGR
Fuga en el sistema de aire de carga
Sensor de la presión diferencial
de EGR
Posibles síntomas
(observados)
Flujo de masa de
EGR sobre el valor
calculado
Piezas necesarias
Número de pieza
Descripción
Cantidad
22181342 / 22172068
(Dependiendo del año del modelo)
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.
© 2020 Volvo Group North America, LLC. Información sujeta a cambios sin previo aviso.
INSTRUCCIONES DE REPARACIÓN DE DIAGNÓSTICO REMOTO
DTC:
P0402-00
Boletín: RD20-026
Fecha: 03 de agosto 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:
• Clavija 1 — Verde/Blanco
• Clavija 2 — Café
• Clavija 4 — Blanco/Café
© 2020 Volvo Group North America, LLC. Información sujeta a cambios sin previo aviso.
INSTRUCCIONES DE REPARACIÓN DE DIAGNÓSTICO REMOTO
DTC:
P0402-00
Boletín: RD20-026
Fecha: 03 de agosto 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:
• Clavija 1 — Verde/Blanco
• Clavija 2 — Café/Blanco
• 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.
© 2020 Volvo Group North America, LLC. Información sujeta a cambios sin previo aviso.
INSTRUCCIONES DE REPARACIÓN DE DIAGNÓSTICO REMOTO
DTC:
P0402-00
Boletín: RD20-026
Fecha: 03 de agosto 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 / 22172068
© 2020 Volvo Group North America, LLC. Información sujeta a cambios sin previo aviso.
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