Cabriolet BPW DPF light / limp mode frustration.

[Fez]

Evening all, I'm really hoping someone might be able to help me out with a persistent DPF issue please. I am one limp mode away from bashing my head against a wall!

a few weeks ago, I had the dreaded BPW Oil pump failure...

I have fitted a recon engine, a brand new turbo, and a brand new DPF (Along with a Bosch DPF pressure sensor) and reset the ash mass calibration using my Launch diag...

 

After around 10-15 miles of driving, I get a DPF symbol appear on the dash, and around another 10-15 miles of driving, eventually get the flashing glow plug light, and the car goes into limp mode. When I check the ash mass in diagnostics, it usually shows between 2 to 4 grams. Re calibrating, and resetting the ash mass to zero (Knowing it really is zero as it has a brand new DPF), the car is fine again, drives and boosts well, until the fault appears again!

I have tried replacing the DPF sensor for a genuine part and I have checked that the pressure sensor hoses are clear and free of splits. The only thing I re-used from the old DPF are the metal pressure pipes, temp sensor and Lambda (Which all appear to be reading an outputting fine in live data. Pre turbo temps under full load usually hover around the 600 to 650oC mark, and settle to around 2-250 when just cruising, off boost.)

Does anyone know of anything else at all that could be causing this please, and where to look next? Thank you! 🙂

[Stevey Y]

20 hours ago, Fez said:

Evening all, I'm really hoping someone might be able to help me out with a persistent DPF issue please. I am one limp mode away from bashing my head against a wall!

a few weeks ago, I had the dreaded BPW Oil pump failure...

I have fitted a recon engine, a brand new turbo, and a brand new DPF (Along with a Bosch DPF pressure sensor) and reset the ash mass calibration using my Launch diag...

 

After around 10-15 miles of driving, I get a DPF symbol appear on the dash, and around another 10-15 miles of driving, eventually get the flashing glow plug light, and the car goes into limp mode. When I check the ash mass in diagnostics, it usually shows between 2 to 4 grams. Re calibrating, and resetting the ash mass to zero (Knowing it really is zero as it has a brand new DPF), the car is fine again, drives and boosts well, until the fault appears again!

I have tried replacing the DPF sensor for a genuine part and I have checked that the pressure sensor hoses are clear and free of splits. The only thing I re-used from the old DPF are the metal pressure pipes, temp sensor and Lambda (Which all appear to be reading an outputting fine in live data. Pre turbo temps under full load usually hover around the 600 to 650oC mark, and settle to around 2-250 when just cruising, off boost.)

Does anyone know of anything else at all that could be causing this please, and where to look next? Thank you! 🙂

Hi was it an original DPF or aftermarket as over my lifetime I have witnessed a host of problems with the aftermarket variety mainly because aftermarket use cordierite cores rather than SIC cores cordierite is cheaper and more dense which makes the pressure sensor think its blocked.

Steve.

[Fez]

54 minutes ago, Stevey Y said:

Hi was it an original DPF or aftermarket as over my lifetime I have witnessed a host of problems with the aftermarket variety mainly because aftermarket use cordierite cores rather than SIC cores cordierite is cheaper and more dense which makes the pressure sensor think its blocked.

Steve.

It's an aftermarket, EuroFlo DPF and yes, it's a corderite core.  Damn, looks like I'm probably going down the DPF delete path and warrantying this one then.

Unless there is any way to 'trick' the pressure sensor like making a small cut in the post-DPF pressure pipe to equal out the pressure reading?

[Stevey Y]

On 7/2/2023 at 9:07 PM, Fez said:

It's an aftermarket, EuroFlo DPF and yes, it's a corderite core.  Damn, looks like I'm probably going down the DPF delete path and warrantying this one then.

Unless there is any way to 'trick' the pressure sensor like making a small cut in the post-DPF pressure pipe to equal out the pressure reading?

Hi on your year of car deleting the DPF is not that big a deal, first came across Cordierite with one of my early cabs MK4 Mondeo, bought an aftermarket DPF for £600, it was a bit of a faf getting it adapted to the car but it went in eventually, BUT it then proceeded to regenerate every 40 miles not good, tried everything but no joy, finally contacted Ford who announced they did refurbished units with a years warranty £360 so I bought one, another 100k and two years no problems, enquired with a Ford tech from Dunton and he explained the difference between OE and aftermarket, on the aftermarket units the soot/ash accumulation chambers are smaller allied to the cordierite core it tells the ECU its blocked or like mine does about 20 regens a night.

Steve.