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Need help with P0402 code.

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brandonchil

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Okay so I have a 2019 TD non HO just bought few months ago. Truck is completely stock. I keep getting a P0402 code “Exhaust Gas Recirculation 'A' Flow Excessive Detected”.
Things I have done. Cleaned EGR Valve 2x. Replaced air filter. Replaced both fuel filters. Cleaned MAP Sensor, and replaced MAF sensor due to reading at idle being in the “20 Gr/Sec” new MAF sensor is reading the exact same reading. When I pull the freeze frame data I notice my barometer pressure is 0 which is weird but my map sensor pressure is around 14.44 psi. I have a scan tool and ran graph data looking and the command and actual value of the EGR Solenoid and it looks good with no abnormalities. I’m lost and need fresh thoughts.
 

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So I have an update. After continuing trouble shooting the issue I finally pulled off my intake air horn and the grid heater was caked in soot “ photo below”. So I ordered the Banks Monster Ram to get rid of the grid that tends to accumulate soot and also to get rid of the death bolt. Not sure if this was my issue yet but will find out soon after I install the new air horn.IMG_5470.jpegIMG_5472.jpeg
 
Maybe the code was correct, “excessive flow detected”

Seems like the thing was stuck wide open for all that soot to be built up. Any chance your egr cooler is busted? Have you been adding coolant?
 
No at this point Egr cooler looks fine. Coolant levels are stable. I just finished installing the Banks Monster Ram which not only removes the dreaded breath bolt but also removes the restrictive grid heater allowing the system to breath easier. At this point my truck ran thru its first regen in months. Which is different than before. Not sure if code will stay gone but will keep this thread updated until I find the fix. Figure others would like to have this information.
 
How many miles? How did the grid heater bolt look? Any signs of it starting to fail?
 
Truck has 130,000 miles. Grid bolt was fine and there was no signs of it failing. So far my P0402 code is gone. Permanent code has also removed its self. Truck seems to be running better. The Banks Monster Ram is a bit expensive verse the other options on the market but I recommend it so far. I am going to install the rest of the banks items on the truck from the CAI, Boost tubes, and the exhaust.
 
Man that seems like a lot of gunk in the intake. Any idea what kind of life the truck lived before you bought it? Grocery getter or work truck? Just wondering if running them hard helps with the soot build up.
 
From what I can find it was between Washington and Michigan a lot so I assume dude was a long hauler. Prior to me buying it the turbo acuator was replace. And all maintenance was completed regularly.
 
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