P0402 and New EGR Valve. - Ford Powerstroke Diesel Forum
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Old 09-01-2012, 11:20 AM
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P0402 and New EGR Valve.

Last fall my CEL came in with P0402. I pulled the EGR valve and cleaned it. About 50 miles later the CEL came back in with the same code.

Fast forward to now. Yesterday I paid for a new EGR valve from the stealership. Today I changed it out. The following picture is the old valve. The shiney black is a grease/tar like consistency. What would cause the soot to take that consistency? My deltas are about 5* and I'm not losing any coolant.


After changing it I cleared codes, and drove it for another 50 miles for the code to clear from resetting it. As soon as it did, I got another P0402 CEL.

What am I missing? I went with the new valve because I cant have this truck down, and my state inspection is coming due so I need the CEL legitemately clear.

I searched and came up with THIS. It says that it's the DPFE sensor, but others say that there isn't a DPFE on a 6.0. If I could get linked to a guide to identify the problem/ fix the problem I would be eternally grateful.

I know that the blue boots for my intake are seeping some oil, but only enough to show where the boots are starting to split. Replacements are in the plan.
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Old 09-01-2012, 03:45 PM
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the EBP sensor is coded DPFE on the motorcraft part number

IT could also be a MAF sensor. I believe P0402 is excessive egr flow? what year is your truck BTW
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Old 09-01-2012, 03:55 PM
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maybe blow by is killing the valve
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Old 09-01-2012, 05:36 PM
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the greasy tar can be from normal oil crankcase vent oil but mostly it's from incomplete combustion or subpar fuel.

Run a fuel additive if you don't, and keep your idle time and short trips to a minimum.
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Old 09-01-2012, 08:21 PM
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Sorry, It's a '07 with about 96k on the clock. My only mods thus far have been a coolant filter and the blue spring mod. I have an oil catch ready to install, but I just haven't done it yet. I try to minimize my idling times, but I typically spend my morning commute in slow moving traffic. I usually add 10oz of silver diesel kleen every other tank during the summer months.Yea P0402 is "excessive EGR flow at idle." Is there a procedure to reteach the ecm the ranges/position of the EGR valve? Maybe it thinks the valve is open when it isn't?

I kept the old valve, and after looking at it again, there is nothing blocking it open or keeping the disks from seating on their seats.

Last edited by Jason_S; 09-01-2012 at 08:25 PM.
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