Opel Frontera UE. Manual - part 822

6E1–171

X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION

difference between the two values exceeds the ECM’s
internal limit, a Diagnostic Trouble Code P0401 will set.
DTC P0401 is a type A code.

NOTE: Several deceleration cycles will be necessary to
run a sufficient number of EGR flow tests to determine a
”pass” or ”fail” condition.

Action Taken When the DTC Sets

D

The Malfunction Indicator Lamp (MIL) will illuminate
the first time the fault is detected.

D

A history Diagnostic Trouble Code is stored.

D

A history Diagnostic Trouble Code will clear after 40
consecutive warm up cycles without a fault.

D

The MIL will turn OFF after three consecutive ignition
cycles in which the diagnostic runs without a fault.

Conditions for Clearing the DTC

D

The MIL will turn OFF after three consecutive ignition
cycles in which the diagnostic runs without a fault.

D

A history Diagnostic Trouble Code will clear after 40
consecutive warm up cycles without a fault.

D

Diagnostic Trouble Codes can be cleared by using the
Tech 2.

Diagnostic Aids

Check for the following conditions:

D

Poor connection or damaged harness – Inspect the
wiring harness for damage. If the harness appears to
be OK, observe the Actual EGR Position display on the
Tech 2 while moving connectors and wiring harnesses
related to the EGR valve. A change in the display will
indicate the location of the fault.

D

Ensure EGR valve is correctly mounted. See
On–Vehicle Service.

Reviewing the Failure Records vehicle mileage since the
diagnostic test last failed may help determine how often
the condition that caused the Diagnostic Trouble Code to
be set occurs. This may assist in diagnosing the
condition.

NOTE: If the EGR valve shows signs of excessive heat,
check the exhaust system for blockage (possibly a
plugged catalytic converter) using the ”Restricted
Exhaust System Check.”

6E1–172

X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION

DTC P0401 – Exhaust Gas Recirculation Flow Insufficient Detected

 

Step

Action

Value(s)

Yes

No

1

Was the ”On–Board Diagnostic (OBD) System Check”
performed?

—

Go to Step  2 

Go to OBD

System

Check 

2

1. Start the engine.
2. Monitor the MAP signal with a Tech 2 while idling.
3. While idling, depress the accelerator pedal about

halfway down and immediately let the engine return
to idle.

Did the MAP value on the Tech 2 show an immediate
large change?

—

Go to Step  4 

Go to Step  3 

3

Replace the MAP sensor.

—

Verify repair

—

4

1. Inspect the exhaust system for modification of

original installed parts or leaks.

2. If a problem was found, repair exhaust system as

necessary.

Was a condition present that required repair?

—

Go to Step  7 

Go to Step  5 

5

1. Remove the EGR valve.
2. Visually and physically inspect the pintle, valve

passages and the adapter for excessive deposits or
any kind of a restriction.

3. If a problem if found, clean or replace EGR system

components as necessary.

Was a condition present that required repair?

—

Go to Step  7 

Go to Step  6 

6

1. Remove the EGR inlet and outlet pipes from the

exhaust manifold and the intake manifold.

2. Inspect the manifold EGR ports and the EGR inlet

and outlet pipes for a blockage caused by excessive
deposits or other damage.

3. If a problem is found, correct the condition as

necessary.

Was a condition present that required repair?

—

Go to Step  7 

Refer to

Diagnostic

Aids 

7

1. Review and record the Tech 2 Failure Records data.
2. Clear Diagnostic Trouble Code and monitor the

Tech 2 System Info Screen while operating the
vehicle as specified in ”Diagnostic Aids.”

3. Using a Tech 2, monitor “Diagnostic Trouble Code”

info for Diagnostic Trouble Code P0401 until the
Diagnostic Trouble Code P0401 test runs.

4. Note the test result.

Does the Tech 2 indicate Diagnostic Trouble Code
P0401 failed this ignition?

—

—

Repair

complete

6E1–173

X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION

DIAGNOSTIC TROUBLE CODE (DTC) P0402  EXHAUST GAS RECIRCULATION

(EGR) EXCESSIVE  FLOW DETECTED

D06RX113

Circuit Description

The Engine Control Module (ECM) closes the Exhaust
Gas Recirculation (EGR) system on engine start–up to
test for excessive (any) flow. If the ECM determines that
EGR flow occurred on start–up, in two consecutive trips,
then DTC P0402 will set. DTC P0402 is a type B code.

Conditions for Setting the DTC

D

Intake Air Temperature (IAT) is above 5

°

C (41

°

F).

D

Engine RPM is less than 500 RPM.

D

EGR Pintle Position if greater than 55 counts.

The above mentioned conditions must be met for 0.6
seconds during engine start–up on two consecutive trips.

Diagnostic Aids

Check for the following conditions:

D

Poor connection or damaged harness – Inspect the
wiring harness for damage. If the harness appears to
be OK, observe the Actual EGR Position display on the
Tech 2 while moving connectors and wiring harnesses
related to the EGR valve. A change in the display will
indicate the location of the fault.

D

Ensure EGR valve is correctly mounted. See
On–Vehicle Service.

Reviewing the Failure Records vehicle mileage since the
diagnostic test last failed may help determine how often
the condition that caused the DTC to be set occurs.  This
may assist in diagnosing the condition.

NOTE: If the EGR valve shows signs of excessive heat,
check the exhaust system for blockage (possible a
plugged catalytic converter) using the ”Restricted
Exhaust System Check.”

6E1–174

X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION

DTC P0402  EGR Excessive Flow Detected

 

Step

Action

Value(s)

Yes

No

1

Was the ”On–Board Diagnostic (OBD) System Check”
performed?

—

Go to Step 2 

Go to OBD

System

Check 

2

1. Review and record the Tech 2 Failure Records data.
2. Clear Diagnostic Trouble Code and monitor the

Tech 2 System Info Screen while operating the
vehicle as specified in ”Diagnostic Aids.”

3. Using a Tech 2, monitor “Diagnostic Trouble Code”

info for Diagnostic Trouble Code P0401 until the
Diagnostic Trouble Code P0401 test runs.

4. Note the test result.

Does the Tech 2 indicate Diagnostic Trouble Code
P0401 failed this ignition?

—

Go to

Diagnostic

Aids 

Go to Step 3 

3

1. Inspect the exhaust system for modification of

original installed parts or leaks.

2. If a problem was found, repair exhaust system as

necessary.

Was a condition present that required repair?

—

Verify repair

Go to Step 4 

4

1. Remove the EGR valve.
2. Visually and physically inspect the pintle, valve

passages and the adapter for excessive deposits or
any kind of a restriction.

3. If a problem if found, clean or replace EGR system

components as necessary.

Was a condition present that required repair?

—

Verify repair

Go to Step 5 

5

1. Remove the EGR inlet and outlet pipes from the

exhaust manifold and the intake manifold.

2. Inspect the manifold EGR ports and the EGR inlet

and outlet pipes for a blockage caused by excessive
deposits or other damage.

3. If a problem is found, correct the condition as

necessary.

Was a condition present that required repair?

—

Verify repair

Refer to

Diagnostic

Aids