P0402 on Chrysler: How to Diagnose & Fix
Exhaust Gas Recirculation Flow Excessive
1 Chrysler model · 1 documented issue · $200-$2,000 repair
P0402 on Chrysler by model: symptoms, diagnosis and fix
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.
Common Symptoms
- Check engine light (EGR codes)
- Rattling noise from underneath when accelerating from cold
- Failed emissions inspection
- Rough idle
- Reduced fuel economy
How to Fix
Replace EGR valve (Mercedes part A6121400060, fits Crossfire directly). Replace catalytic converter if rattling. Many Mercedes SLK R170 parts are direct replacements at lower cost. Use Mercedes dealer or independent Mercedes shop for best results.
Sources for this issue (1)
P0402 code reference
General diagnostic-code context. The code alone does not confirm a cause for your vehicle; use the applicable issue card and its sources.
Frequently asked questions
What does P0402 mean on a 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 it is documented across 1 model: Crossfire.
What are the most common causes of P0402?
The most common causes of P0402 are: 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. The specific cause varies by vehicle.
How much does it cost to fix P0402 on a Chrysler?
Published repair estimates on Chrysler range from $200 to $2,000 depending on the model and root cause. If an issue mentions a recall or campaign, check your VIN with the manufacturer or NHTSA and confirm eligibility and coverage with a dealer.
Looking for P0402 on a different make?
View P0402 across all makes →Content compiled with AI assistance using NHTSA complaints, TSBs, and owner reports. May contain errors. Always verify with your vehicle's service manual.