Bob's Mechanical Repairs

Ford P0402

Bob's Mechanical Repairs — independent family-run garage in Birnam, Dunkeld, Perthshire. Call 01350 727 276 or email [email protected].

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EGR flow excessive on Ford diesel — sticking EGR valve stuck open, carbon-loaded on 1.6/2.0 TDCi.

Ford P0402 — EGR flow excessive on Ford diesel — sticking EGR valve stuck open, carbon-loaded on 1.6/2.0 TDCi. Typical UK independent garage cost: £180–£850.

What actually causes P0402 on a Ford

PSA-shared 1.6 TDCi (DV6): the EGR valve carbons up and physically can't close — MAF sees too much recirculated gas. On 2.0 TDCi Transit we see the EGR cooler crack internally, which flows uncontrolled gas back and looks like an EGR-open fault.

Ford engines that log P0402

  • 1.6 TDCi DV6 (Focus, C-Max, Mondeo)
  • 2.0 TDCi (Mondeo, S-Max, Galaxy)
  • 2.2 TDCi Transit

How we diagnose P0402 on a Ford

  1. Live-data EGR duty vs actual flow — commanded 0%, actual >5% = stuck open
  2. Remove EGR valve, inspect for carbon lock and cracked seat
  3. Inspect EGR cooler for internal crack (pressure test)
  4. Clean intake manifold when fitting new valve — mandatory

The common misdiagnosis to avoid

Fitting a new EGR valve without cleaning the intake manifold — the fresh valve chokes on carbon within 5k miles. Also, EGR delete is illegal for road use in the UK and MOT emissions will fail.

Ford P0402 repair cost in the UK

Expect £180–£850 including parts and labour at an independent garage. Main-dealer quotes on Ford are usually higher for the same job, and the spread exists because the cheap cause and the expensive cause throw the same code — pay for the diagnosis before you pay for parts.

Bob's workshop tip

1.6 TDCi DV6 — always Delphi OE EGR valve, and always clean the manifold. Pattern valves fail within a year.

Codes usually seen alongside P0402 on Ford

  • P0401
  • P0403
  • P0404

Symptoms drivers report with P0402

  • Rough idle, often shaking the gear lever
  • Hesitation off the line
  • Stalling at junctions
  • Possible black smoke at idle
  • Engine warning light + power reduction warning

Repairs that clear P0402

  • EGR clean or replace
  • Sensor inspection

For the generic, all-makes explanation of this code — meaning, every known cause and UK cost bands — see our P0402 guide.

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