Relay 2.2 DPF cleaning keep vehicle moving

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LittleOldSuzi
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Relay 2.2 DPF cleaning keep vehicle moving

Post by LittleOldSuzi »

The 2014 2.2 Relay is displayed DPF cleaning keep vehicle moving last night before a 3 hour drive home but it never went out, still on this morning so clearly we have a problem.

What are the options on these vans? I know the replacement are eye watering but can they be cleaned or even drilled out? Are there any sensor issues that flag a blocked DPF that is actually fine?

Cheers
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Re: Relay 2.2 DPF cleaning keep vehicle moving

Post by GiveMeABreak »

First off, we don’t condone any permanent removal /drilling out of DPF or emissions equipment as its anti social and illegal for a vehicle using public roads. See A7 of the user policy:

viewtopic.php?t=56502

These days it’s not the end of the world, as DOFs can either be removed for cleaning / deep cleaning, or in many cases can be cleaned in situ on the vehicle, using special DPF cleaner.

The vehicle is obviously trying to regenerate, hence the message you are receiving, but short journeys or those in slow moving traffic / stopping of the vehicle can interrupt the process.

Although the engine ECU will attempt several times to complete a regeneration, if the process is interrupted too many times it will flash up the warning.

You really need to get a diagnostic tool on it to determine the soot blockage levels and the regeneration history to try and determine the cause.
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Re: Relay 2.2 DPF cleaning keep vehicle moving

Post by RichardW »

How many miles has it done? At 100k + they decide the DPF is full and put the light on. You can probably get away with telling it you've changed it and it will go for a good while yet.
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Re: Relay 2.2 DPF cleaning keep vehicle moving

Post by LittleOldSuzi »

OK well the van has had a bit of a mare by the looks of it. 3 codes that were not there when I serviced it 1000 miles ago. All cleared and a 10 minute drive brings nothing back yet.

P0488 - Stuck EGR valve is listed as intermittent
P0423 - Atomiser for injection of fuel at exhaust? No idea....
P1490 - Conditions for regeneration of DPF not fulfilled.

Cheers
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Re: Relay 2.2 DPF cleaning keep vehicle moving

Post by GiveMeABreak »

Can you pop the VIN up so I can relate the codes correctly.
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Re: Relay 2.2 DPF cleaning keep vehicle moving

Post by LittleOldSuzi »

Sure, it is VF7**************[VIN obfuscated, can be read by forum staff].
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Re: Relay 2.2 DPF cleaning keep vehicle moving

Post by GiveMeABreak »

Ok so this is what I have for those errors - you have a Siemens injection system on this Ford Puma 130 engine.

Looking at the codes you can now see that in order for the particle filter to regenerate, it has to close the EGR valve. Therefore, it is likely that the P0488 code is P048872 - the Stuck open fault. As the EGR valve is not closing on command, the particle filter sequence will not start and therefore the filter is getting blocked up.

As a matter of some urgency, I would focus on the EGR valve issue itself, because no regeneration will be permitted when it is locked open. Once your particle filter gets to anywhere near 75% full or above, the risk of it never being able to regenerate when you do fix the EGR fault increases significantly - so I would stop using the vehicle! If it then becomes unable to regenerate using the system, it will have to come off for a deep clean....

So that is where I would focus my efforts. Try the EGR fix first, but I would get it looked at to see if it needs changing, then that should clear the other faults. I would then try and force a regeneration with a diagnostic tool (only after you have changed the EGR valve if necessary), or if the diagnostic tells you the EGR valve is opening and closing correctly again. Hopefully you have caught it in time. Your P0423 fault may also be related to the regeneration that is not taking place...

P0423 Atomiser for injection of fuel at the exhaust: Internal fault

Conditions for fault activation:
The following conditions have to be met:
  • - Ignition on
  • - Particulate filter regeneration
  • - Coolant temperature above 50°C
Conditions of disappearance of the fault: None
Downgrade Mode: None
Warning: -
Symptoms:
  • No effects immediately perceptible to the customer
  • Smoke from the exhaust
  • Fluid leak/smells (diesel fuel, oil, etc.)
  • Possible absence of automatic stopping of the internal combustion engine
Suspect Areas:
  • Electrical harness
  • Connectors
  • PEF upstream temperature sensor
  • Vaporiser
  • Catalytic converter upstream temperature sensor
  • Catalytic converter
  • Particle filter
  • Metering pump fuel supply circuit
  • Metering pump for injection of fuel into the exhaust
P0488 There should be another part of the code - either 72 or 73:

P048872 - EGR Valve Stuck Open or P048873 - EGR Stuck Closed

In either case, to try and clear this, you should start the engine, run the car for 4 minutes, then stop the engine and wait for 1 minute.

Suspect Areas: EGR Valve / Connectors or Electrical Harness

P1490 Again this should be followed by 68 or 72 at the end of the code, but generally:

Particle filter: Driving conditions for regeneration of the particle emission filter not fulfilled.
  • Detection of a particle filter overload: The difference in particle filter pressure is above a maximum threshold.
  • The soot load is greater than 16 g/l
  • The time of appearance of the fault code is 5s
Downgrade Modes:
  • Switching to fuel "normal reduced flow" mode.
  • Prohibiting of regeneration of the particle emission filter and stopping of the requests in progress.
  • Request for closing of the EGR valve.
Warning Lamp: MIL

Symptomes Likely:
  • No effects immediately perceptible to the customer
  • Lack of power
  • Starting problem
  • Fluid leak/smells (diesel fuel, oil, etc.)
  • Smoke from the exhaust
Suspect Areas:
  • Tappings for the differential pressure sensor of the particle emission filter
  • Electrical harness
  • Connectors
  • Particle filter upstream temperature sensor
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Re: Relay 2.2 DPF cleaning keep vehicle moving

Post by LittleOldSuzi »

Thanks for the info. I have a busy week next week but the following Monday/Tuesday I will strip off the EGR valve as a starting point. The extra part of the code on P0488 was 73 so it appears to be sticking closed.
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Re: Relay 2.2 DPF cleaning keep vehicle moving

Post by GiveMeABreak »

Ok, good luck with the investigation.
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Re: Relay 2.2 DPF cleaning keep vehicle moving

Post by LittleOldSuzi »

Just taken the van back to the Midlands for the week and 1 code has returned. P0423 92 and it is listed as Permanent fault. Nothing else has flagged so it appears the extra injector that supplies the fuel directly into the exhaust might be the culprit. I did find a YouTube video that says this extra injector can blow a fuse in the engine bay but didn't say which one, any ideas?

PP2000 list the following log with the error code:
Engine RPM: 2611
Speed: 113 Kph
Accelerator position: 53%
Coolant Temp: 67C
Soot in particle filter: 7 G/l
Cat upstream temp: 452C
Particle filter upstream temp: 396C
Flow of gas through particle filter: 0
Distance travelled since last regeneration: 0
Activation of the diesel injection at exhaust dosing pump plug coil: Yes
Activation of the diesel injection at exhaust dosing pump: No
Regeneration in progress: Yes

Seems interesting that the plug activated but the pump didn't. Mean anything? Thanks again....
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Re: Relay 2.2 DPF cleaning keep vehicle moving

Post by LittleOldSuzi »

I just checked the 3 fuses and they are all fine so that is OK. Back to work to earn some money....
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Re: Relay 2.2 DPF cleaning keep vehicle moving

Post by LittleOldSuzi »

OK we have found the fault, that was the easy bit. The 5th injector/fuel atomiser that supplies fuel directly into the exhaust during DPF regeneration is blocked. Easy test is to unplug the fuel feed hose from the tiny fuel pump on the subframe and blow down it. The 'injector' is just a straight pipe with an extra glow plug, if you can't blow down it then it is blocked and the DPF will fail to regenerate.

Apparently you can clean them out rather than spend £130 on a new one but it is on the exhaust pipe above the subframe. Can someone please take a look at the manual and tell me how the hell I get it off? Thanks.
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Re: Relay 2.2 DPF cleaning keep vehicle moving

Post by GiveMeABreak »

Here you go:
Suzi E.PNG
Suzi A.PNG
Ok, so the item is number (22) above.This is the Plug Kit

Here's how you remove and refit it:
Suzi B.PNG
Suzi C.PNG
Location

The vaporiser (1) is to be found on the precatalyst (2).

Removing:

Disconnect the battery.
Place the vehicle on a 2-post lift.
CAUTION: Blank all the apertures of the
fuel high pressure circuit using the Plug Kit.


Disconnect the connector (at "b").
Unclip the pipe (3) (at "c").
Uncouple the pipe (3) (at "a").
Remove the vaporiser (1).
Suzi D.PNG
Refitting

Adhere to the Tightening Torques! see end of procedure for torque settings.

Position the boss ("d") on the vaporiser (1)
in the spline of the precatalyst (2) (at "e").

Refit:

The vaporiser (1).
Clip the pipe (3) (at "c").
Connect the connector (at "b").
Couple the pipe (3) (at "a").

Reconnect the battery.
Clear the memory of faults using the diagnostic equipment.

Repriming the vaporiser

CAUTION: After having performed a repair or a replacement either of the vaporiser, of the metering pump or of the pipe linking the metering pump to the vaporiser, it is necessary to perform the "metering pump replacement" procedure in the RP (replacement parts) menu using Diagbox.

Prime the vaporiser circuit using the diagnostic tool (note the S1279 additional add-on module may be needed for the VCI for commercial vans, or the VCI may not be able to communicate with the relevant system.

Tightening Torques:
Suzi F.PNG
ReferenceDescriptionTightening torque (daNm)
(1)Oxygen sensor4,5 daNm
(2)Turbocharger clip2,3 daNm
(3)Vaporiser4,8 daNm
(4)Fixing of pre-catalyser2,5 daNm
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LittleOldSuzi
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Re: Relay 2.2 DPF cleaning keep vehicle moving

Post by LittleOldSuzi »

Thanks very much. A job for the weekend....
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Re: Relay 2.2 DPF cleaning keep vehicle moving

Post by LittleOldSuzi »

OK it is off and there is a really easy way to do it. After days of struggling I took the battery and tray out and it is right there. Took 10 minutes to get the battery and tray out the way, another 10 to free the heatshield and wiring, heated it up with a soldering blow torch and she can off fine. Pictures to follow.

I have cleaned the first inch but it is still blocked, what is the best chemical to dissolve this carbon?

Thanks...
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