I have a problem with my dpf, the car keeps going into limp mode and reads P2002.
On average it throws the error about each tank of fuel. The engine runs great, very smooth, the mpg is averages at about 44mpg. Its a good car...except!

This P2002 error, the dpf warning light doesn't come on, it doesn't flash or anything, it simply goes out when I start the engine.

For those who have had this error, did your dash dpf warning light come on?

Finally, I dont need to do a Regen, I have discovered that if I just leave it for a few days of pottering, when I cancel the fault, it stays off for another tank of fuel. I used to do a forced regen each time - but I had to change the oil twice in a couple of months, anyway I discovred that forced regeneration makes no difference on the mileage between errors being thrown.

I have had the error code is thrown at clogging levels of between 60%, 80%, 100% and 120%. It seems odd that sensors would surely have a datum point at which the error is thrown, so to be able to drive with clogging levels at 120%, twice that of what had previously thrown the same fault is confusing.

I have ordered a new pressure sensor differential and adjoining flexible pipe, and will report back.

The Dobby is a great car, I do lots of miles on and off the motorway, but I just cant continue driving around in limp mode with a my OBD11 tool in the boot.

It would be interesting to hear of other peoples experiences, my error seems to be triggered at low revs or when de-accelerating, like I say, it doesnt to be force regened, nor does it Regen automaticly:bang:

I have had my ERG valve changed.....there's not a lot left.........also my car has now done 90K...the engine is as sweet as a nut, that is a nut that drives you mad

I think I have discovered my problem.

I think I need a new turbo, there is no smoke, rattling or loss of power. However I do have a slight amount of end float on my impeller I believe that oil from the bearing is passing the seal and entering the exhaust - clogging the dpf.
I think its only leaking oil at certain revs, so it can burn itself of after a run at 70mpg.

Who would have thought...the turbo

There has to be a certain amount of movement in the turbo shaft, otherwise, the oil wouldn't circulate round and create a "bearing" of oil.

Now if you said the blades were hitting the plenum, I would be worried.

There will always be a tiny bit of oil bypassing the seal and ending up in the exhaust, but that is normal.

What I would suggest is, when was the oil last changed? I would do it every 6k if short journeys and 10k for longer (motorway) journeys.

Use the best oil recomended for your car.

Perhaps check the pressure sensor is functioning 100%, they do tend to soot up the pipes and the sensor will read higher that the actual DPF is producing.

It's a bit like water flowing through a garden hose, kink it a bit and the pressure will build, but the flow reduce.

Andoo said:

There has to be a certain amount of movement in the turbo shaft, otherwise, the oil wouldn't circulate round and create a "bearing" of oil.

Now if you said the blades were hitting the plenum, I would be worried.

There will always be a tiny bit of oil bypassing the seal and ending up in the exhaust, but that is normal.

What I would suggest is, when was the oil last changed? I would do it every 6k if short journeys and 10k for longer (motorway) journeys.

Use the best oil recomended for your car.

Perhaps check the pressure sensor is functioning 100%, they do tend to soot up the pipes and the sensor will read higher that the actual DPF is producing.

It's a bit like water flowing through a garden hose, kink it a bit and the pressure will build, but the flow reduce.

Click to expand...

Thanks for your help, Ive bought a sensor and pipe and will be fitting it this weekend, Id like to think it isn't the turbo. When it comes to not spending money....I love been proved wrong regards the oil, its just been changed with castrol EDge

For owners of Mutlijet 1.9 (120)

The part number for the DPF pressure sensor is
55204352


Here is a link to a supplier: http://www.ht-onlineshop.de/elektri...1792301-1-3-d-fiat-500-panda-169-neu/a-76497/




I bought mine from Fiat main dealer and it cost £70, I just couldn't find a part number anywhere, boy could I have got it cheaper

Ok Here's an update:
Changed the differential pressure sensor...no joy
Changed the DPF temp sensor...no joy
New oil and counter reset...no joy...I could get the DPF to auto regenerate if I sat in the passenger seat cancelling error codes, usually after about 20 minutes it would regen. You might expect a technical officer on a Boeing Dreamliner, but not in a Fiat Disappointment.

So I Cut the bottom off the DPF (whilst still on the car) the DPF was clean, not just a little, but very clean, completely unblocked
Removed the filter and welded it back together...set fire to my hair..in a big way....and burnt a hole in my hip the size of of a pot noodle . Oh Joy

I've taken the Filter out of the DPF and I'm having the ECU reprogrammed Monday 14th July for £100.

If all is well after this, then I'll buy a second hand DPF- preferably a blocked one,, then I'll cut and weld it off the vehicle (unfortunately because of the positioning there are no heat shields to hide the repair behind so it will have to be an invisible fix....when the DPF is off the car that will be no problem, in addition, Ive also learnt that due to the lack of heat shields, I will need to weld in some strengthening plates into the empty DPF, If you tap it now, its obvious its empty.

( I should at this stage explain that I used to be an engneer of repute, but I now have a broken spine so welding an exhaust with the car on axle stands is difficult, especially with very limited movement bellow the waist and my hair on fire, I'm just glad that my large burn, which came from rolling on the hot welding torch is on my very paralyzed side.)

Incidentally, I think the reason the Doblo has so many DPF problems is that the DPF unit simply replaced the expansion box on the older JTD models, unfortunately, this is fully exposed meaning the DPF is effectively air cooled, and furthermore, its too far away from the manifold, by the time the gasses have reached the DPF they have cooled considerably. Many of these DPF problems could be easily cured by offering a retro fit kit that places the DPF nearer the engine.

I'll keep everyone informed if the reprogram of the ecu works. Thanks for all your help I'll let you now tomorrow how my Fiat Disappointment is running. In the mean time, if anyone has an old blocked DPF for sale, message me, once Ive weaved my magic on the second DPF
I will take my car to the exhaust center and get them to swap it over. JD...Job Done

Sorry to hear about your burn. You need to keep it clean, especially if you can't feel anything. Irrigate regularly with saline solution and change the dressing after each irrigation. Perhaps some Germoline or similar to keep bacteria at bay.

You would have been better to remove the DPF and replace it with a straight pipe as a get you by, but we live & learn.

I was thinking, the cat could be removed and the DPF put in it's place.

A diesel doesn't benefit from a cat in the same way a petrol does, but removing those soot particles is a good thing.

I have to add, I have no DPF as it was stolen, so it was mapped out of the equation along with the EGR. Now, I have hot exhaust. So much so, my damn leg touched the end at the bumper and I howled with pain

I had only driven 23 miles too

Andoo said:

Sorry to hear about your burn. You need to keep it clean, especially if you can't feel anything. Irrigate regularly with saline solution and change the dressing after each irrigation. Perhaps some Germoline or similar to keep bacteria at bay.

You would have been better to remove the DPF and replace it with a straight pipe as a get you by, but we live & learn.

I was thinking, the cat could be removed and the DPF put in it's place.

A diesel doesn't benefit from a cat in the same way a petrol does, but removing those soot particles is a good thing.

I have to add, I have no DPF as it was stolen, so it was mapped out of the equation along with the EGR. Now, I have hot exhaust. So much so, my damn leg touched the end at the bumper and I howled with pain

I had only driven 23 miles too

Click to expand...

I did intend to take off the DPF, except the nuts/bolts holding it on where corroded quite badly and it will need some gas to remove them.
Hopefully my man with the computer might be able to keep my EGR in the map and only delete the DPF, that should control engine temp better.

I cant belive that you had your DPF stolen....! At least you can be sure it wasnt me that nicked it, if it had been you could have just folowed the smell of burning pork like a Bisto kid and it would have led you straight to me.

Thanks for your advise regards my burn, I now look an idiot, half my hair is missing and I'm spreading Germoline over my burn as though it were butter - still my teenage boy cant stop laughing.

Good to hear you are looking after the burn. They are the worst for bacterial infection.

I don't think the EGR will have any effect on actual engine temp, but it can help lower exhaust gas temperature and has some effect on emissions.

Anyway, don't worry about your hair, just do what I do and shave the bloody lot off

OK Update 2

The DPF has been deleted from the ECU, it took some time to download the software from the ECU, but eventually it completed.

The DPF, EGR were deleted and the software reinstalled.

I was really worried about it not working or causing big problems....but nothing, it just worked.

As for the car, it is transformed, the MPG is up to 50 - 52 mpg and for a 1.9 that's good. But the biggest change is in the driveability of the car.

It's difficult to put my finger on how its changed, but the best way to explain it is, it just wants to go, especially at low revs, the acceleration is so much better and the power delivery is so much smoother.

I have yet to find a used DPF to swap over at MOT time, but I'll deal with that in good time, all I can say for now is that having the DPF cored and deleted has turned my car from a Fiat Disappointment, back into my Fiat Doblo. It now drives like a diesel, it rolls for miles on the overrun and I can change up a gear way sooner than I used to be able to.

When its MOT time (April 2015) I'll update again.

Fibnaly the guy I used to flash my ECU is based in Warrington, he works part time and has all the kit, he charged me just £100 for which he will include a performance or eco map if you wish, that's way cheaper than anyone else I could find.

I'll happily insert an image of his business card if anyone is interested (I have no connection to guy other than he fixed my car, so this is not advertising)

My burn doesn't seem as bad now, although I think I can see a little bone.

OK, I promised an update, so here it is.

The 'Greenhouse' went in for her MOT this week. I was a bit nervy as I have had the DPF cored out and the ECU reprogrammed.

Anyway, it passed the MOT no problem, she passed the opacity smoke test easily.

I did change one thing though, last week I hired a car ramp for £20 an hour, I got Dobby in the air to check my welding wasn't leaking. I would love to say it was perfect, but unfortunately, there were a couple of pin holes, I was a bit disappointed but considering that I still have a large indented hole in my body from laying of a red hot welding torch for 3 minutes, I didn't do a bad job.

Luckily I had considered this possibility and so had bought my welder, so fixing this was not a big problem. I had also been worrying about how the Doblo doesn't have any close fitting DPF heat shields that would hide the welding marks.

As the date of the MOT grew ever closer, these worries became ever more present. Normally, I'm a great sleeper, but I began tossing and turning at night, running through the possibilities of what might happen if they saw the welding marks, what if the guy doing the MOT is a hard arse, I was losing sleep and getting a little grumpy. Then I came up with the answer, I thought, DPF's get very hot and so its normal for this to have heat shields, 3 minutes later and I had bought 15 meters of heavy duty exhaust heat wrap and 4 or 6 s/s zip ties. We (my son and I) spent about 15 minutes neatly wrapping the DPF with the tape. It looked great! and it sailed through the MOT.

I would never advise anyone to remove your DPF, all I can say is it worked for me, it has transformed my car, I was losing confidence in it, that beep beep fault note was something that I dreaded and it spoiled the enjoyment of driving the Greenhouse. Immediately after removing the DPF and deleting the DPF & EGR from the ECU, Dobby was transformed. She pulled better, she had better MPG and most importantly, she was much more flexible right through the rev range. Whatever the right and wrongs of removing the DPF, I am so glad I have done it, Dobby is better than she was when she came out of the factory, you cant argue with that!