DPF regeneration indicator (2006.5 Transit only)
E98563
It is not always the case that vehicles are operated in the temperature ranges required for regeneration of the DPF.
The indicator indicates to the driver when there is a risk of the DPF becoming overloaded.
Illumination of the indicator signals to the driver that the vehicle needs to be operated at a higher engine speed to initiate and complete an active regeneration process.
To this end, the vehicle should be driven at a higher engine speed for at least 30 minutes. Long periods of idling should be avoided.
The indicator goes out again following successful regeneration. The vehicle can now be used as normal.
If the required active regeneration process cannot be successfully completed, in addition to the DPF regeneration indicator, the MIL is also switched on.
If this happens, the vehicle must be brought to the nearest Authorised Ford Dealer. The technician can initiate active regeneration using the IDS.
If in addition to the DPF regeneration indicator and the MIL the transmission control indicator is also switched on, a new DPF must be installed.
Note: If the vehicle is mainly operated with sufficient exhaust gas temperatures, it is very possible that the DPF regeneration indicator will never come on. With sufficient exhaust gas temperatures, the vehicle is always able to independently initiate and complete the necessary regeneration processes.
Intake manifold flap
Installation position
Illustration shows the system with vacuum control
E98519
The intake manifold flap is located in a housing that is mounted directly on the intake manifold.
Purpose and function
A high temperature (approx. 600 °C) is needed to burn off the diesel particulates trapped in the DPF. This temperature, however, is not attained in all of the engine's operating conditions.
Under certain operating conditions, the intake manifold flap is partially closed in the lower partial load range.
The resulting lack of fresh air intake results in the combustion chambers no longer being cooled as sharply.
This helps to increase the exhaust gas temperature.
Coated diesel particulate filter (DPF) Lesson 6 – Engine Emission Control
Components of the engine emission control system
1
3
4
5
6
7 8
9
10 2
11 1
3
4
5
6
7 8
9
10 2
11
E98520
Catalytic converter exhaust gas temperature sensor
1
DPF exhaust gas temperature sensor 2
DPF differential pressure sensor 3
MAP sensor 4
Intake manifold flap position sensor (only with vacuum-controlled systems)
5
PCM 6
CAN 7
DLC 8
Intake manifold flap solenoid valve (only with vacuum-controlled systems)
9
Fuel injector 10
Intake manifold flap unit (with systems with electrical actuator unit)
11
Service instructions
Before installing a new PCM or before loading new software as well as after installing a new DPF
differential pressure sensor, always read the instructions in the current Service Literature.
Lesson 6 – Engine Emission Control Coated diesel particulate filter (DPF)
Exhaust gas temperature sensor(s)
Installation position
E48497
One or two sensors are installed, depending on the system.
System with one sensor:
• The sensor is located immediately upstream of the DPF.
System with two sensors:
• One sensor is located upstream of the oxidation catalytic converter and
• one sensor is located immediately upstream of the DPF.
Purpose and function
The exhaust gas temperature of at least 550 °C to 600
°C required for burning off the diesel particulates is detected by the sensor(s) and transmitted to the PCM.
Depending on the exhaust gas temperature calculated, the PCM decides whether or not the regeneration process can be initiated.
Effects of faults
In the event of a fault, the PCM calculates a substitute value.
Specific regeneration of the DPF, however, is no longer possible.
Diagnosis
The monitoring system checks:
• the sensor for short circuit to ground/battery and open loop,
• logical rise/fall rate of the signal, whereby
intermittent faults are detected (e.g. loose connector contacts),
• for plausibility.
DPF differential pressure sensor
Installation position
E59691
The differential pressure sensor is located in the engine compartment, near the bulkhead.
Purpose and function
The sensor measures the current exhaust gas pressure upstream and downstream of the DPF and determines the differential pressure based on the readings.
For this purpose there is a pipe connection upstream and downstream of the DPF.
The readings are converted by the sensor into a voltage signal and transmitted to the PCM.
The soot particles and ash collected in the DPF result in a change in pressure in the exhaust gas stream upstream and downstream of the DPF. The altered pressure value owing to the ash/soot load is used by the PCM as an input variable for determining soot and ash load.
Coated diesel particulate filter (DPF) Lesson 6 – Engine Emission Control
Furthermore, the sensor detects a defective DPF.
Effects of faults
If the sensor is defective, the PCM calculates the timing of the next regeneration.
Overloaded or blocked DPF:
• The PCM continuously calculates the load status of the DPF from the engine's operating conditions and from the input variable of the sensor.
• With an increasing soot load, the engine torque is also continuously reduced.
• If the DPF is blocked, the MIL is set.
Diagnosis
The monitoring system checks:
• the sensor for short circuit to ground/battery and open loop,
• the measured sensor values for plausibility (comparison with the map data).
Via the sensor, the monitoring system detects:
• an overloaded/blocked DPF. (The pressure drop across the filter is too great and the differential pressure exceeds a calibrated maximum value.)
• a defective/missing DPF. (The pressure drop across the filter is too low and the differential pressure falls below a calibrated minimum value.)
Service instructions
With some systems, it is necessary to carry out a parameter reset using the IDS after installing a new sensor. In this regard, always refer to the instructions in the current Service Literature.
Intake manifold flap position sensor (vacuum-controlled systems)
Installation position
E97945
The sensor is installed at the intake manifold flap housing, near the intake manifold flap.
Purpose and function
In vehicles with coated DPF, the exact position of the intake manifold flap has an effect on the active regeneration process (see the section "Intake manifold flap" in this lesson).
The sensor works inductively (contactless) and is therefore insensitive to slight contamination.
The sensor is supplied with a reference voltage (5 V ± 5 %). The analogue output signal to the PCM is between 5 and 95% of the reference voltage.
Effects of faults
Specific regeneration is only possible to a limited extent.
In extreme cases, this leads to overloading of the DPF and thus to reduced engine power output.
Diagnosis
The monitoring system checks:
• the sensor for short to ground/battery (by means of a limit range check) and open loop,
• the logical rise/fall rate of the signal, whereby intermittent faults are detected.
Service instructions
Following installation of a new sensor, it must be initialised using the PCM (refer to the instructions in the current Service Literature).
Lesson 6 – Engine Emission Control Coated diesel particulate filter (DPF)
Intake manifold flap unit
Installation position
Intake manifold flap unit with integrated actuator motor and position sensor
E98522
The unit is mounted directly at the intake manifold.
Purpose and function
The intake manifold flap is partially closed as required during the active regeneration process. This helps to increase the exhaust gas temperature.
The intake manifold flap unit consists of the following components:
• intake manifold flap,
• actuator motor,
• position sensor.
The intake manifold flap is operated by a DC motor.
Actuation is performed via PWM by the PCM.
The current position of the intake manifold flap is detected by a position sensor (potentiometer). The output signal is an analogue voltage signal.
Effects of faults
Specific regeneration is only possible to a limited extent.
In extreme cases, this leads to overloading of the DPF and thus to reduced engine power output.
If the intake manifold flap becomes jammed closed, the engine cannot be started.
Diagnosis
Intake manifold flap unit monitoring is divided into the following steps:
• Monitoring of the DC motor via the PCM output stage
• Monitoring of the position sensor:
– Limit monitoring: the PCM constantly checks if the incoming signal is within the limits.
– Monitoring for short circuit and open circuit.
– Reference voltage monitoring.
• Monitoring of the intake manifold flap:
– The position sensor detects a jammed or sticking intake manifold flap.
Service instructions
With some systems, it is necessary after installing a new intake manifold flap unit to carry out an initialisation using the IDS. In this regard, always refer to the instructions in the current Service Literature.
Coated diesel particulate filter (DPF) Lesson 6 – Engine Emission Control
General
1
2
3 4
2
5 6 7
8
9 1
2
3
4
2
5 6 7
8
9
E98530