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Home >> Suzuki >> 2001 >> XL-7 Limited >> Repair and Diagnosis >> External Pages >> Different car >> Section 5 (Engine Controls - Self-Diagnostics) >> Diagnostic Tests >> DTC P0402: Exhaust Gas RECIRCULATION Pintle Crank Error >> Diagnostic Procedure

Diagnostic Procedure

WARNING: This page is about a different car, the 2002 Isuzu Trooper. However, it is still accessible from the selected car via links, so may be relevant.
  1. Perform ON-BOARD DIAGNOSTIC II SYSTEM CHECK  under SELF-DIAGNOSTIC SYSTEM. After performing OBD-II system check, go to next step.
  2. Turn ignition on. Review and record scan tool FAILURE RECORDS data. Operate vehicle within FAILURE RECORDS conditions. Using scan tool, monitor SPECIFIC DTC information for DTC P0402 until DTC P0402 test runs. If scan tool indicates DTC P0402 FAILED THIS IGNITION, go to next step. If scan tool display is not as specified, check for an intermittent problem. See DIAGNOSTIC AIDS .
  3. Disconnect EGR valve 5-pin harness connector E-33. EGR valve is located at right rear of intake manifold. Check for poor, loose or corroded connections in EGR valve and harness connector. If problem is found, go to next step. If no problem is found, go to step  5.
  4. Repair or replace damaged terminals or connections. After repair is complete, see VERIFYING VEHICLE REPAIR  under SELF-DIAGNOSTIC SYSTEM.
  5. Remove EGR valve. Check for foreign material between seat and pintle. If foreign material is present, go to next step. If foreign material is not present, go to step  7.
  6. Remove foreign material from EGR valve. Check pintle and seat for damage. If no damage was present that would affect operation of EGR valve, go to next step. If damage was present that would affect operation of EGR valve, go to step  8.
  7. Reinstall EGR valve. Start and run engine at idle. Using scan tool, use special functions to check EGR operation. If EGR operates correctly, system is okay. If EGR does not operate correctly, go to next step.
  8. Replace EGR valve. After repair is complete, see VERIFYING VEHICLE REPAIR  under SELF-DIAGNOSTIC SYSTEM. If DTC P0402 still fails SPECIFIC DTC test on scan tool, go to next step.
  9. Replace and reprogram PCM. See POWERTRAIN CONTROL MODULE REPLACEMENT  under POWERTRAIN CONTROL MODULE. Use scan tool to clear DTC and verify repair.
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