Yet another Mondeo with DPF problems.

[gais_el]

Don't get me wrong, I love this car, but there are so many horror stories that when I saw the "Engine Malfunction" I knew sh*t hit the fan. 

 

Ford Mondeo 2.0 TDCi (UFBA - i think) from December 2010, but model 2011 with around 310.000 km. 

On Monday got the "Engine Malfunction" up scheduled a mechanic visit towards the end of the week. In the mean time run my small OBD with Forscan and got the at the end of the post. Until I got it to the mechanic the check engine light came on as well and the car went into limbo mode. 

 

After one day at the mechanic he said that he tried to make a manual regeneration and it failed. After some diagnostics he found that the temp. sensors were gone as well as a crack int he rubber fitting near the pressure sensor. 

Fitted new temp. sensors and fixed the rubber crack, started another manual regeneration that completed. Called me to pick up the car. 

 

Literally, on the way back from the mechanic, on the motorway I could hear that is was doing a regeneration when the "Engine Malfunction" came back and the regen stopped. 

 

Called the mechanic in the morning he said that most probably will need a new filter but he first wants to take it down and check everything to make sure I actually need a new one. 

 

Also because he said that a new one from his supplier would be ~1k euros in local currency which is a bit pricy and he would like to take it down so he can look maybe on other shops for a better price. 

 

Anyone any recommendations?

===PCM DTC P246C:00-AF===

 

Code: P246C - Particulate Filter Restriction - Forced Limited Power (Bank 1)

Status:
- DTC Present at Time of Request
- Malfunction Indicator Lamp is On for this DTC

Module: Powertrain Control Module

Freeze Frame :
-GLOBTIM: 336116377 s - Global real time
-TOTDIST: 310853.0 km - Total Distance
-MAINECUV: 14.00 V - Main ECU voltage supply
-ESTSERUN: Yes - Engine status - engine running
-ESTSECRK: No - Engine status - engine in crank
-INCARTMP: 27 °C - In car temperature
-OUTTMP: 28 °C - External Temperature From Sensor
===END PCM DTC P246C:00-AF===

===PCM DTC P246B:00-2F===
Code: P246B - Vehicle Conditions Incorrect for Particulate Filter Regeneration

Status:
- DTC Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Powertrain Control Module

Freeze Frame :
-GLOBTIM: 336110170 s - Global real time
-TOTDIST: 310842.0 km - Total Distance
-MAINECUV: 12.00 V - Main ECU voltage supply
-ESTSERUN: No - Engine status - engine running
-ESTSECRK: No - Engine status - engine in crank
-INCARTMP: 29 °C - In car temperature
-OUTTMP: 23 °C - External Temperature From Sensor
===END PCM DTC P246B:00-2F===

===PCM DTC P2463:00-AF===
Code: P2463 - Particulate Filter Restriction - Soot Accumulation (Bank 1)

Status:
- DTC Present at Time of Request
- Malfunction Indicator Lamp is On for this DTC

Module: Powertrain Control Module

Freeze Frame :
-GLOBTIM: 336110170 s - Global real time
-TOTDIST: 310842.0 km - Total Distance
-MAINECUV: 12.00 V - Main ECU voltage supply
-ESTSERUN: No - Engine status - engine running
-ESTSECRK: No - Engine status - engine in crank
-INCARTMP: 29 °C - In car temperature
-OUTTMP: 23 °C - External Temperature From Sensor
===END PCM DTC P2463:00-AF===

===OBDII DTC P246C-C===
Code: P246C - Particulate Filter Restriction - Forced Limited Power (Bank 1)

Status:
- Confirmed - malfunction is confirmed

Module: On Board Diagnostic II

===END OBDII DTC P246C-C==

[unofix]

An 11 year old car with over 192000 Miles, I'm amazed that it hasn't needed a new DPF before now. Can't say if a €1000 is expensive but I would think it's about right.

[gais_el]

Ah maybe that is indeed the case. Tho i was under the impression if it is driven ok, it should be able to regenerate and maintain the filter....

[unofix]

1 minute ago, gais_el said:

it should be able to regenerate and maintain the filter....

not forever, eventually they become full of ash that can not be burnt away.

[MasterTechTip]

1 hour ago, gais_el said:

===PCM DTC P246B:00-2F===
Code: P246B - Vehicle Conditions Incorrect for Particulate Filter Regeneration

Usually indicates the vaporiser is blocked. Did your mechanic check this as it's extremely common?

[gais_el]

9 hours ago, MasterTechTip said:

Usually indicates the vaporiser is blocked. Did your mechanic check this as it's extremely common?

I've seen that this is quite common issue causing the DPF to fail (at least on forums). I have indeed ask to check the injectors and he said that all 5 were ok. 

[Frembrit]

The vaporiser completely blocked up on my car when it was on approx. 66,000 miles in 2017. Have a read here (note: the pressure sensor was ok in my situation)

It does sound like you need a new vaporiser, then reset the DPF learned values and go for a drive.

[gais_el]

Just got a word from the mechanic, he said he started, he started pulling apart the system and checking each component to find what causes the conditions not to be met while driving. So far he said that the fuel pump for the fuel vaporizer doesn't push enough fuel so even if the vaporizer is ok, during the regen it doesn't get enough fuel sprayed in to get to the needed temperature. 

[gais_el]

Sorry for a late reply, after some more diagnostics with my mechanic. It turned out there were 2 things that caused the issue.
1. The DPF pump would not pump enough diesel for the fuel vaporizer

2. The fuel vaporizer was restricted

 

which resulted in very little diesel getting to the dpf during the regeneration. Changed the vaporizer with a new one and the pump with a used - the mechanic said that he has never seen these pumps failing and the used parts guy said that he has sold only one before so I went with a used one in hope it will last.

Now it seems to be fine, I try to monitor the regenerations, the soot level (both load and the other one) never get to 0 but they do grow during city driving and drop after a nice ride on the motorway.
 

This is just just when I got the car. After a ~week of city driving is this: 

 

sorry that I changed the order of the first two :D. The DPF load grew very little for some reason. And a few days after a motorway drive:

 

 

I will still try to keep an eye on it to see how it behaves.

 

On another note anyone any suggestion why my LOW_OIL is YES?

 

And big thank you to everyone that participated in the discussion!

[gais_el]

Also quick question should  I be worried if the dog pressure is 0 when idling? It does go up when I rev it up

[Peter Miles]

Hi All,

 

Had continual problems DPF error warnings, forced burns etc etc.

In the end, a mechanic friend used some DPF Cleaner, removed a sensor and used the whole can.

No more warning lights, and she is running like new again. Ford workshop had it over 13 days in total, always got it back and within hours the warning light was back on.

All perfect now.