DPF Removal Repair Ford Transit Custom 2.2: Step-by-Step Fix

Clogged DPF? In this guide from O'Rileys Autos, we tackle a Ford Transit Custom with engine management light issues and reduced power. You'll see the full process of diagnosing faults, removing the DPF, cleaning it off the vehicle, and testing everything back on. This hands-on approach helps van owners spot similar problems early and avoid costly breakdowns. Initial Diagnosis: Spotting the DPF Issues We started with the basics on this Transit Custom. The engine management light glowed bright, signaling trouble. Using the Launch X431 Euro diagnostic tool, this tool is available from www.launchtech.co.uk live data showed about 40 mbar of DPF pressure and a DPF at 218% full, way over capacity. Fault codes painted the picture: * P244C: Exhaust temperature too low on the DPF. * P2463: Soot accumulation blocking the DPF. * A glow plug fault, which we set aside for now. These triggered limp mode, limiting power for safety. We checked under the van and found the vaporizer seized tight. It wouldn't budge without full removal. For customers, we offer choices: on-car cleaning for soot at a lower cost, or off-car back-flushing for both soot and ash. With over 100,000 miles on this one, removal made sense for a deeper clean. Why Remove the DPF? Challenges with This Van Seized vaporizer added extra hassle, likely blocking fuel flow and causing the low temperature fault. Removing the whole DPF let us back-flush it properly. This method blasts out soot and stubborn ash buildup, restoring flow better than on-site options. Prepping the Engine Bay: Removing the Airbox and Cover Inside, the air filter had collapsed from heavy blockage. Air struggled to pass, deforming the filter. We've seen this lead to turbo damage when bits break off and enter the intake. We caught it just in time. To reach the DPF, we lifted the engine cover. This exposed the three top bolts mounting the DPF to the turbo: one front, one middle, one rear. . Under-Vehicle Work: Disconnecting Sensors and Vaporizer We disconnected pressure hoses, sensors, and rubber mounts. The vaporizer plug used a simple press-and-release. Rust slowed things, but light taps separated parts cleanly. No splits occurred. Extracting the DPF Unit: The Big Pull Once loose, we pried the joints apart. A wiggle and some taps freed the DPF fully. Testing and Replacing the Vaporizer We tested the old vaporizer first. Connected a Laser pressure gauge to the fuel line end; it read blocked. For the fix, we fitted a new vaporizer. Steps included: 1. Pull off the connector. 2. Attach the gauge and check for flow. 3. Inspect and confirm the blockage. This addressed the temperature fault directly. We blocked sensor holes and the tube end for proper setup. Back-Flushing on the Carbon Clean Machine Over at our van, we prepped the Carbon Clean DCS16 machine. this is available from www.carbon-clean.co.uk Joined the water pressure line and taped a small leak to avoid splashes. With the new vaporizer in, we blocked other ports so pressure went straight through. The process filled the DPF, then blasted in cycles: 1. First run pushed out black soot. 2. Second revealed red ash mixed in. 3. Cycles three to five cleared more ash; water turned lighter. 4. By six or seven, it ran mostly clear with just a faint red tint. Black meant soot, red signaled ash. Reinstallation: Reversing the Process Refitting followed reverse steps. We pushed the DPF up into place and tightened front and rear mount bolts. Post-Repair Resets and Checks Back inside, we used the scan tool's special functions. We reset the particle filter learn values to update soot loading after cleaning. Engine Test: Revs and Pressure Readings We fired up the engine and held 3,000 RPM briefly. This dried condensation, with pressure starting high then dropping. At idle, it settled to 3.5 mbar. Revving hit 58-63 mbar, then eased to 52. Final Touches: New Air Filter and Wrap-Up A fresh air filter arrived, so we installed it to stop future collapses. All faults cleared now. The DPF sat clean, vaporizer new, ash flushed out, and everything refitted. All is good on this Transit Custom. Powertrain functions confirmed the reset.