P0402 on Volvo
Exhaust Gas Recirculation Flow Excessive
P0402 on Volvo vehicles indicates exhaust gas recirculation flow excessive. Au7o has documented this code across 2 Volvo models — most commonly on S90, XC60. 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 Volvo range from $300 to $4,500, 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 Volvo by Model
Volvo S90(1 issue)
- Sensus Infotainment System Lag, Crashes, and Black Screen2017-2023
The Sensus infotainment system in the S90 suffers from significant lag, screen freezes, and black screen episodes. Since the system controls climate, seat heating, navigation, and vehicle settings through the central touchscreen, a crash renders many vehicle functions inaccessible. The system runs on a Tegra K1 processor that struggles with the software load, especially when running multiple features simultaneously. Volvo has released numerous software updates, and the transition to Google-based Android Automotive OS in 2024 addressed the hardware limitations but introduced new software bugs.
Volvo XC60(2 issues)
- Aisin TF-80SC 8-Speed Transmission Shudder and Harsh Shifting2018-2022
The Aisin Warner TF-80SC 8-speed automatic transmission used in the XC60 T5 and T6 can develop shuddering during light acceleration at 30-50 mph and harsh 1-2 and 2-3 upshifts. The torque converter lockup clutch is the primary culprit, with fluid degradation accelerating the issue. The transmission control module (TCM) software has been updated multiple times by Volvo to address shift quality. Some units require torque converter replacement. The issue is more prevalent in vehicles driven primarily in stop-and-go traffic.
- Four-Corner Air Suspension Compressor and Strut Failure2018-2024
XC60 models equipped with the optional Four-C (Four-Corner) air suspension system can experience compressor failure and air strut leaks, typically after 60,000-80,000 miles. The air compressor works overtime to compensate for slow leaks in aging air struts, eventually burning out. Symptoms start with the vehicle sitting lower on one corner after sitting overnight and progress to complete suspension failure with the car sitting on the bump stops. Cold weather accelerates air spring rubber degradation. The system uses Continental air struts.
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View P0402 across all makes →Frequently Asked Questions
What does P0402 mean on Volvo?▼
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 Volvo specifically, this code is documented across 2 models.
What causes P0402 on Volvo vehicles?▼
Common causes on Volvo: 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 Volvo?▼
Repair costs on Volvo range from $300 to $4,500, depending on the specific model and root cause.
Which Volvo models have P0402 documented?▼
Au7o has documented P0402 on 2 Volvo models: S90, XC60.