Reasons a dpf might fail/crack internally

[RadioSurfer]

Hello,

I’m having a new dpf fitted (Ford not aftermarket) to a 2020 Connect 1.5 Ecoblue, after the original was found to have a cracked filter core. What can make a core fail? I want to make sure I’ve investigated and remedied as far as possible any potential engine causes. Reasons I can think of are; 1) simply age/mileage - the failed one was 5 years old and 110,000 miles. I’d expect it to last much longer 2) Thermal shock such as hitting water. 3) Manufacturing defects, it seems Ford did have an issue with some pre 2019 dpf’s with a recall notice where the outer casing separated from the filter core. 4) Forced regenerations, Jimmy O’Riley (sometimes referred to as the dpf king) is very anti this as he feels it can crack the dpf. 5) Bad design, again if you watch Jimmy O’Riley’s videos, he has his doubts over the design.

Any other thoughts, or engine issues that might cause the dpf to mechanically fail? I’ve checked the turbo for oil leak, and it seems fine. I’m struggling to think of any other engine causes.

Cheers, Richard.

[metalworker0]

I would like to help , but simply don't know
if looking at O'Riley vids hasn't given you the answer then no one can!
Putting this into google gets you a load of answers "reasons for dpf cracking"

putting this in "BEST MAKE OF DPF" UK has this answer

Top-rated DPF (Diesel Particulate Filter) brands in the UK for quality and reliability include OEM-level suppliers like Faurecia (Easy2Fit), and high-quality aftermarket specialists such as BM Catalysts, Krosfou, and EuroFlo. These brands are noted for using durable materials and offering extensive warranty coverage, with Krosfou particularly recognized for wide compatibility and BM Catalysts as a leading manufacturer.


Top DPF Brands in the UK:

Faurecia (Easy2Fit): Renowned for Original Equipment (OE) quality and expertise, often considered top-tier for performance.

BM Catalysts: Europe's largest independent manufacturer of DPFs and catalytic converters, offering high-quality aftermarket solutions.

Krosfou: Highly regarded for providing high-grade, durable, and affordable stainless steel DPFs, popular for various car makes in the UK.

EuroFlo: Known for offering a unique, industry-leading 3-year warranty on their ISO-accredited, high-quality units.

European Exhaust and Catalyst (EEC): A reputable manufacturer known for producing high-standard aftermarket DPFs in the UK.


Key Considerations for Choosing a DPF:
Warranty: Look for brands offering at least a 2-year warranty (e.g., EuroFlo offers 3 years).
Quality Standards: Ensure the product meets ISO 9001/TUV accreditation for durability and emissions compliance.
Fitment: "Easy2Fit" type products, such as those from Faurecia, often come with necessary fitting accessories.

Note : ive not heard of any of them .. not having ever done any research into this , 6 years .. i would expect longer than that .. 110,000 miles .. perhaps that's fare usage .. I really don't know ... we will have to wait what others will say if they can be bothered... it's like you'd have to own a van and done 500,000 miles to find out the answers .. by then other new manufacturers appear, others disappear, manufacturing methods change, i doubt even ford themselves never tested the endurance of them.

i had a cat break up once from getting the tuning of an LPG system wrong .. that's it... that's my only experience .


All the best.mark

[RadioSurfer]

Hi Mark,

As always, thanks for the comments and taking time to respond, it is appreciated. Let’s see if anyone has any other thoughts to add.

I’ve done a lot of research, and the general consensus seems to be don’t use aftermarket, they are not much cheaper than original, and often last only months if not weeks. O’Riley is not very complimentary about the Connect exhaust set up in particular, and regularly says something must be wrong with the design. I’ve mentioned elsewhere, he is working with a company based in Chesterfield to make changes to the ECU on Audi Q5’s to sort out their disastrous dpf failure rates. I hope he looks at the Connect as well, but suspect there is not the money to be made on a Ford van compared with an expensive Audi.

Maybe, in the end, stuff just isn't designed to last. At one time you would often hear people say a diesel will last virtually forever as long as you change the oil regularly. I think Euro 6 requirements have pushed the technology beyond its capabilities, but we are where we are.

In theory, a new dpf and a complete exhaust and Cat should give me another 100,000 miles. If so, great. I was very lucky to get the complete post dpf exhaust and Cat system for £130, genuine Ford, from a van that was written off with only 7 miles on the clock on a Ford dealer’s forecourt. Someone’s misfortune is definitely my gain in this instance.

There’s just that niggle in my mind, that something else might be causing the dpf to internally crack and fail, but don’t have the technical understanding to think what that might be.

Cheers, Richard.

[dumper]

H I you watch O’Reillys on YouTube and when problem vehicles have come to him after others have failed and fitted new DPF are you sure you cured the problem that caused the DPF to fail in the first place?

[metalworker0]

what dumper said .. don't fit that new cat until you've investigated .. a few things that could have caused it .. you'll be familiar with most... i'm Just listing a few of the most likely...

1 Over-fueling caused by hole in the booster pipe .. open EGR .. MAF sensor fault.

2 Lamda sensor ( never tasked about here)--- the FIRST sensor in the exhaust system ... see's the 02 concentrations and from this info, the pcm works out fueling ratio - note sellers and ebayers call the last one the NOX sensor a lamda .. which is confusing.
To diagnose .. you'll be looking at the live data graph, it makes an alternating switching pattern of voltage in forscan - oscilloscope section.
The graph is never perfectly symmetrical .. here, it tells you how to understand the graph .. not necessarily forscan.. shows good graphs and bad graphs , so you can see the difference between a good and a bad sensor.

https://www.hexgs911.com/tech-info/lambda/

3. Vaporiser .. blocked


all the best.mark

[RadioSurfer]

This is what I need, suggestions on what could be causing the dpf to fail. Looking at your points in detail:

1) Boost pipe replaced already as a precaution, the original wasn’t actually split but I know it’s a very common issue. EGR stuck is a possibility, as is poor MAF sensor. If that were the case I’d expect other symptoms to show such as poor idling, difficult starting, lumpy drive, DTC codes. But it runs as sweet as a nut, nothing to suggest anything wrong here. But, I will check both of those.

2) First Nox sensor (as Ford call it), referred to as the Oxygen sensor by O’Riley is a possibility, but again a smooth easy drive and a combined 50mpg, which seems very reasonable. If it was overfueling wouldn’t I be seeing a dip in mpg? I don’t have Forscan, to double check. I’ll have to think about this one. Incidentally, just looking on eBay to get an idea of price, and in the first 6 I looked at, 2 were temperature sensors, 1 a particle sensor and 1 Nox sensor 2. You have to be very careful, and not rely on peoples descriptions.

3) No vaporiser in this type of dpf, so not an issue here.

Any more thoughts?

Cheers, Richard

[metalworker0]

Has the car had the software updates .. ford make corrections to their mistakes .. early custom and mk8's 2.0l ecoblues had an over-fueling issue on the re-gen .. as you say: no vaporiser, ive come to the conclusion, its the same system of over-fueling, to do the re-gen .. was corrected by a software update by ford .. as it was putting too much fuel in , caused DPF problems and oil dilution problems. piston ring and bore wear.

viewtopic.php?p=1611014

All the best.mark

[RadioSurfer]

Morning Mark,

I’ve checked with Ford, no recalls or updates for my vehicle.

Cheers, Richard.

[andz327]

not sure about your engine but usually its repeated forced regens on blocked dpf's without cleaning dpf properly, or possible cheap replacement parts not up to the job

Sent from my SM-G990B using Tapatalk

[RadioSurfer]

Morning @andz327,

I agree, I’ve watched too many O’Riley videos now, and know he strongly advises against it. I’m not going to allow any garage to try a forced regen in the future. As far as I can tell, parts are original Ford. But, as the van is relatively new to me, I don’t know its history, and now suspect someone has had a go at sorting it in the past, given up as a bad job and “dressed” the van for sale.

If you watch O’Rileys videos he’s not very complimentary of the Connect in particular, and he has seen enough people in similar positions to consider the design not fit for purpose. It seems that once dpf issues arise, it’s difficult to get out of. I’m convinced there is an engine issue that causes the problem. Leaking injectors, failing turbo, or something that results in either oil getting through, or a poor combustion resulting in excessive soot, maybe a failed MAF sensor, or stuck/blocked EGR.

Garages seem to struggle to diagnose any issues with it, other than saying these engines do create a lot of soot that can block manifolds. Maybe it needs an old fashioned decoke, not one of the hydrogen spray approaches. There are no fault codes now the dpf is sorted, and it drives as good as any vehicle I’ve owned.

I suppose, I just have to work through bit by bit, and keep a very close eye on it. I’ve had some good suggestions here to work through, but no clues from the engine yet to allow me to focus in any particular area.

Cheers, Richard.

[metalworker0]

Well i haven't got your model .. but looking at pictures .. am i right ? that the whole thing is sort of at an angle and next to the engine and in the engine compartment ... that would say to me:
1. Not in the wind draft so gets very hot .. and isn't cooled as much as one slung under the floor of the van.
2. And that, any forced re-gen with the car static and not moving, would cause tremendous heat build up.

all the best.mark

[RadioSurfer]

Thanks to everyone who responded,

Everything I’ve read to date, or watched, states that there are three common problems with the 1.5 L engine in the Connect, these being; the dpf blockages - despite being used in many other Ford vehicles, stuck EGR valves and associated blockages, and head gasket. Of course adblue, and NOX controls to meet Euro 6 are an issue across all vehicles and not unique to the Connect.

Therefore, I’m going to replace the EGR valve with an original new one that I’ve got for £23, it’s not worth the effort of cleaning the old one at that price. I’m considering a refurbished original Garrett turbo, just in case it’s starting to let some oil through and clog the dpf. Garrett turbos aren’t what they were, as usual compromising quality for profit. Several manufacturers no longer use Garrett, but it is the original so I’ll go with refurbished. A new set of reconditioned fuel injectors once I see how things go, I suspect they are leaking very slightly, and finally a proper old fashioned decoke, when I can find someone.

I can’t do much more, and just keep fingers crossed it gets sorted.

I’ll let you know how things progress.

Cheers, Richard.