P0402 on Chrysler
Exhaust Gas Recirculation Flow Excessive
P0402 on Chrysler vehicles indicates exhaust gas recirculation flow excessive. Au7o has documented this code across 2 Chrysler models — most commonly on Crossfire, Sebring. P0402 means the Exhaust Gas Recirculation (EGR) system is flowing too much exhaust back into the intake. The EGR system intentionally routes a small amount of inert exhaust gas into the engine to lower combustion temperatures and reduce nitrogen-oxide emissions, but the flow must be metered precisely. When the PCM determines the flow is excessive — often because the EGR valve is stuck open or letting gas through when it shouldn't — it sets this code. Too much EGR can cause rough idle, stalling, hesitation, and a check engine light. Typical repair costs on Chrysler range from $200 to $2,000, depending on the specific model and root cause.
Common Causes of P0402
- •EGR valve stuck open or not closing fully
- •Failed or sticking EGR valve diaphragm/solenoid
- •Carbon buildup holding the EGR valve open
- •Faulty EGR position or differential pressure (DPFE) sensor
- •Leaking EGR valve gasket or pintle seat
- •Vacuum control or solenoid fault commanding EGR open
- •Wiring or connector problems in the EGR control circuit
P0402 on Chrysler by Model
Chrysler Crossfire(1 issue)
- EGR Solenoid and Catalytic Converter Failure2004-2008
The Crossfire (built on Mercedes SLK R170 platform, sharing 80% of components) commonly experiences EGR solenoid failures and premature catalytic converter failure. The EGR solenoid is the most common cause of check engine lights. Catalytic converter rattles and fails, especially noticeable when accelerating from cold.
Chrysler Sebring(1 issue)
- Alternator and PCM-Integrated Voltage Regulator Failure2001-2010
The Sebring's voltage regulator is integrated into the PCM (Powertrain Control Module), not the alternator. This unusual design means a voltage regulator failure requires PCM diagnosis/replacement rather than simple alternator work. Alternators also fail prematurely around 70,000 miles. Ground corrosion and battery terminal strip issues compound the problem.
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View P0402 across all makes →Frequently Asked Questions
What does P0402 mean on Chrysler?▼
P0402 stands for "Exhaust Gas Recirculation Flow Excessive." P0402 means the Exhaust Gas Recirculation (EGR) system is flowing too much exhaust back into the intake. The EGR system intentionally routes a small amount of inert exhaust gas into the engine to lower combustion temperatures and reduce nitrogen-oxide emissions, but the flow must be metered precisely. When the PCM determines the flow is excessive — often because the EGR valve is stuck open or letting gas through when it shouldn't — it sets this code. Too much EGR can cause rough idle, stalling, hesitation, and a check engine light. On Chrysler specifically, this code is documented across 2 models.
What causes P0402 on Chrysler vehicles?▼
Common causes on Chrysler: EGR valve stuck open or not closing fully, Failed or sticking EGR valve diaphragm/solenoid, Carbon buildup holding the EGR valve open, Faulty EGR position or differential pressure (DPFE) sensor, Leaking EGR valve gasket or pintle seat. Specific causes vary by model and year — see the per-model sections below.
How much does it cost to fix P0402 on a Chrysler?▼
Repair costs on Chrysler range from $200 to $2,000, depending on the specific model and root cause.
Which Chrysler models have P0402 documented?▼
Au7o has documented P0402 on 2 Chrysler models: Crossfire, Sebring.