Hello,

I have finally admitted defeat, there's nothing else to check or test, the DPF must be at fault.

After considering all the options, I will be replacing it with an aftermarket part.

I'll update this thread with any problems I come across, and will take pics during so probably make a guide to help others as I haven't found one.

Anyway, first thing is to make sure I've got everything, will be ordering today so most things will turn up next week. List is:

DPF inc fitting kit (BM Catalysts) - £200

1 litre PAT fluid inc top up kit - £38

Oil (Mobil Super 3000 X1 FE 5w30) - £28

Oil filter (1109 AY genuine PSA one, identical to Ford but cheaper) - £5.50

Magnetic Sump Plug and Washer - £5.50

EGR blank - £3.35

No labour costs as I'll be fitting myself but that comes to ~ £280 all in.

Have I missed anything off the list??

Now, onto fitting.

It looks reasonably simple as follows -

Remove engine top cover, undertray, airbox, metal boost pipe and fan cowling.

Remove sensors and pipes from DPF

Remove heatshields from DPF

Remove lower DPF to mid-pipe bolts

Remove V band clamp from turbo

Unbolt and lower the DPF through out underneath the vehicle

Place new DPF, bolt up and tighten clamp and lower bolts.

Replace heatshields, sensors and pipes

Replace fan cowling, boost pipe, airbox, undertray and top cover (unless changing oil)

Go to the rear of the car, locate additive filling plugs/clips

Clip pipe to additive tank, screw cap onto additive bottle

Hold bottle high, upside down, allow gravity to force additive into tank.

Remove bottle and pipes, replace dust covers to stop dirt getting into the tank.

Inside car with laptop and FORScan

Clear any fault codes

Do the 'Refill additive tank' procedure

Do the 'prime additive' procedure

Do the 'Reset DPF learned values' procedure

Start the engine and run it up to temp, may drive it to aid this, the do the 'static regen' procedure.

Check for fault codes

Assuming all is well, change the oil and filter (change after the regen so as not to put diesel into the fresh oil!) and also fit EGR blank at this point.

Again, anything I have missed there??

Cheers

Tom

think you have nailed it on the head there!

Bit late James, I did it yesterday.

Well half of it!