How to: Diesel Particle Filter Removal

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Doggy
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How to: Diesel Particle Filter Removal

Post by Doggy »

Now that a fully tested method exists to completely remove the DPF system, I thought I would condense the various posts down to one, comprehensive HOW-TO - here goes....

The diesel particle filter, ('DPF' or 'FAP'), requires cleaning or replacement periodically, (typically 50k, but varies wildly according to driving conditions), the Eolys additive also needs to be topped up & counters reset by your friendly, not-for-profit, Pug dealer. This little lot can set you back £600 or more.

The system is as shown below:
Image

Item 11 is the CAT c/w downpipe & flexy section: 12 is the DPF

On the car, it looks like this:

Image

Once it's removed, the inside looks like this:
Image

(It's also bl00dy heavy).
The filter element was then knocked out, leaving debris like this:

Image

Inside now looks a little more free flowing.....

Image

and MUCH lighter - 4.1 kg lighter, in fact!

Got it re-fitted & then MOT'ed - passed the emissions test easily, (limit is 3.5, actual value 1.14, don't know the units, mg/m3 or ppm)?

Needless to say - it's not that simple. :roll: After a couple of months, I got a permanent ANTIPOLLUTION FAULT & limp mode. :cry:

I assumed that the only way to get to the bottom of what it was unhappy about would be via dealer diagnostics, so bought myself a Lexia / PP2000 clone on eBay for £ 155, then couldn't get it to work on my car, though it worked on virtually every other Pug I tried...(more later).

One of the guys on the coupe club, then made THE BREAKTHROUGH

The FAP code can be deleted from the ecu file using software called 'Ecusafe'. (This isn't generally available, but there were some bootleg versions to be had a while ago). Anyway, one of the coupe guys posted how to do it and a second posted links to example files, with and without the FAP deleted.

Unfortunately, one of the posts linked to examples of 180 bhp remapped files, (also with & without FAP), which the coupe mods felt exposed their forum to possible legal action by the tuning company that had produced the files originally. As a result, virtually all the info has been taken down and continues to be removed whenever anything is posted on the subject.

It's not my intention to post anything similar here, but if interested forum members PM me, I'll try to point them in the right direction.

(Yours truly just happened to be lurking in their neck of the woods during this, 'window of opportunity'). :twisted:

You will also need an ecu flash-programming lead to enable you to copy files to & from your car's ecu via the EOBD port. I used a Galletto 1260, purchased via eBay for about £ 25. I understand a KWP2000 will work too, perhaps there are other compatible, 'ecu flashers' out there?

The Galletto is a little interface box, which plugs directly into the EOBD port, (hidden behind the cover next to the headlight height adjusting switch), plus a USB lead to plug into your laptop. Comes with a mini DVD with the software and absolutely no instructions. I took a guess and just copied everything to a folder I'd created under Program Files, (called Galletto), & knocked up a desktop shortcut pointing to EOBD1260.exe & it worked.

.....Or at least the software started up, but it wouldn't talk to my car either, just like the PP2000 clone we mentioned earlier. :cry:
But there was now a clue - the Galletto has a red LED which should light when you plug it into the car - mine didn't. Eventually, discovered this was down to a blown fuse in the engine fusebox, that powers the 'vehicle' side of the interface. Fuse replaced and Galletto
can now 'find' the car. Needless to say PP2000 worked now too. :roll:

Using PP2000, I read the engine ecu fault codes - there were about 5 separate messages, all relating to the additive ecu. I cleared all the faults, but didn't start the engine so they wouldn't come back.

Next, I swapped to Galletto and copied my original ecu file off the car at least three times saving each on different media after checking all reported the same checksum via Galletto, so fairly sure I could restore it if need be.

Then I copied a standard 136 bhp no-FAP file I'd got via the coupe forum links to the ecu, started her up and hey presto - no faults, no limp mode, happy doggy. 8)

I have now covered about 4k miles with no problems whatsoever.

I've also checked the car with PP2000 - I won't go into detail, but it's obvious it no longer 'cares' about the DPF. It also makes no attempt to regenerate it, thus avoiding the fuel wasted in this operation. The car just behaves as if the FAP never existed. 8)

Though I have not yet done this, I am sure it is now possible to remove the various sensors, additive tank, additive injector, additive ecu and so on.

Since completing the work on my car, I came by a copy of Ecusafe and can confirm it will disable the FAP system in seconds, generating a no-FAP file ready to download. Works for just about every other car too, as far as I can tell.


To recap, the process involves physically removing the guts from the DPF or 'FAP' AND re-programming the engine ecu to delete the FAP system. It can be done in this order, or the software can be done first, but recognise that without active regeneration, the FAP will block, probably within a few hundred miles, perhaps sooner.

You don't necessarily need access to PP2000, but it may be needed to clear some faults.

You don't have to have your own Galletto, but as it's so cheap and lets you upgrade or restore the original files at will, I definetely recommend it.

BE CAREFUL! It is possible to lock the ecu if anything goes wrong during the flashing process, leaving an ecu in need of specialist attention and a dead car!


mods - please use this to replace the original 'How TO: Diesel Particle Filter Removal- The Final Solution?' in the KB
2002 HDi 2.2 Exec Estate, (2008-12) (wonderful)
2003 HDi 2.2 6-speed Exec Estate (2012-19) (also a gem)
2009 Citroen C5 2.0 HDi VTR+ Estate (godawful heap)
2008 BMW E91 330i touring (great fun - murdered by a reversing SUV)
2007 BMW E91 325i touring (slower smoother quieter)
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steve_earwig
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Re: How to: Diesel Particle Filter Removal

Post by steve_earwig »

Shant :P Mainly because of the Kango pictures :twisted:
Unskilled meddling sin©e 2007

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Doggy
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Re: How to: Diesel Particle Filter Removal

Post by Doggy »

Well, Picasso had his 'blue period'....

- maybe this is Steve's 'power tool period' ?
2002 HDi 2.2 Exec Estate, (2008-12) (wonderful)
2003 HDi 2.2 6-speed Exec Estate (2012-19) (also a gem)
2009 Citroen C5 2.0 HDi VTR+ Estate (godawful heap)
2008 BMW E91 330i touring (great fun - murdered by a reversing SUV)
2007 BMW E91 325i touring (slower smoother quieter)
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steve_earwig
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Re: How to: Diesel Particle Filter Removal

Post by steve_earwig »

Maybe, I do own 8 drills...
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teamster1975
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Re: How to: Diesel Particle Filter Removal

Post by teamster1975 »

Moving to KB, good job Doggy & thanks for sharing :)
1996 406 1.8LX Got a bad case of hydro lock!
1996 406 Executive 2.0 Turbo XU10J2TE No longer hangin' on in there :(
1997 Honda CB500V
2003 Volvo V40 1.8 GDi SE killed by a nutter in a beemer 5 series
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steve_earwig
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Re: How to: Diesel Particle Filter Removal

Post by steve_earwig »

Now twice on the KB :lol: (I thought it would be an idea if I left this one behind for any comments )
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teamster1975
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Re: How to: Diesel Particle Filter Removal

Post by teamster1975 »

steve_earwig wrote:Now twice on the KB :lol: (I thought it would be an idea if I left this one behind for any comments )
Doh! You should have mentioned that you'd copied it Steve! :oops:
I've moved this one back out :lol:
1996 406 1.8LX Got a bad case of hydro lock!
1996 406 Executive 2.0 Turbo XU10J2TE No longer hangin' on in there :(
1997 Honda CB500V
2003 Volvo V40 1.8 GDi SE killed by a nutter in a beemer 5 series
2008 Mondeo 2.0 TDCi Titanium X

"Always look on the bright side of life, dedo, dedo dedodedo"
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Re: How to: Diesel Particle Filter Removal

Post by steve_earwig »

Yeah, sorry 'bout that, I just thought... (you know what Thought thought...)

[/rambling]
teamster1975 wrote:good job Doggy & thanks for sharing :)
Zigactly, 'tis a very splendid post indeed :cheesy:
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teamster1975
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Re: How to: Diesel Particle Filter Removal

Post by teamster1975 »

steve_earwig wrote:Yeah, sorry 'bout that, I just thought... (you know what Thought thought...)
Mate the way things are in the teamy household at the moment my marbles are long gone :lol: :lol:
1996 406 1.8LX Got a bad case of hydro lock!
1996 406 Executive 2.0 Turbo XU10J2TE No longer hangin' on in there :(
1997 Honda CB500V
2003 Volvo V40 1.8 GDi SE killed by a nutter in a beemer 5 series
2008 Mondeo 2.0 TDCi Titanium X

"Always look on the bright side of life, dedo, dedo dedodedo"
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srdan
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Re: How to: Diesel Particle Filter Removal

Post by srdan »

Hello there,
I have Peugeot 406 2.2 HDI (year 2002).
I would like to remove complete FAP system (including additive tank).

For several days I am looking step by step re programing ECU, but no success here :(
Can you please help me how to do this.

If I am thinking right I have to do this before removing the system:

1. take the ECU file with some software and create a backup file
- which EOBD cable and which software?

2. than I have to find all references to FAP and additive tank
- what do I have to look, search? keywords..fap?

3. after that how do I remove exact all those references and not more ecu stuff...

4. will there be a problem because additive tank will not be present, would ECU see that something is missing,
hope regeneration would not came out or home limp mode...or minimum additive level notifications or fap errors...

After physical removing there will no be:
2 sensors on FAP filter, additive tank (additive level, injection pump for that additive tank...and so on).

please advice
maybe there is possible to get original P406 2.2 HDI binary file without FAP system?

BR, Srdan
PEUGEOT 406 2.2 HDI
- DE-FAPPED
- EGR OFF
- IDLE SPEED OPTIMIZED (835 RPM)
- PRO TUNED
- LOOKING FOR 6 GEAR ML6C (CITROEN C5 2.2 HDI YEAR 2001-2003) TRANSMISSION ...
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Doggy
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Re: How to: Diesel Particle Filter Removal

Post by Doggy »

srdan wrote:Hello there,
I have Peugeot 406 2.2 HDI (year 2002).
I would like to remove complete FAP system (including additive tank).

For several days I am looking step by step re programing ECU, but no success here :(
Can you please help me how to do this.

If I am thinking right I have to do this before removing the system:

1. take the ECU file with some software and create a backup file
- which EOBD cable and which software?
Galletto 1260 or similar, (available on eBay, about £25).
2. than I have to find all references to FAP and additive tank
- what do I have to look, search? keywords..fap?

3. after that how do I remove exact all those references and not more ecu stuff...

4. will there be a problem because additive tank will not be present, would ECU see that something is missing,
hope regeneration would not came out or home limp mode...or minimum additive level notifications or fap errors...

After physical removing there will no be:
2 sensors on FAP filter, additive tank (additive level, injection pump for that additive tank...and so on).

please advice
maybe there is possible to get original P406 2.2 HDI binary file without FAP system?
Yes it is. PM me a direct e-mail address & I'll send you the necessary file(s)

After reprogramming & removing the FAP element, you could remove the sensors, additive tank etc. or just leave them there......
2002 HDi 2.2 Exec Estate, (2008-12) (wonderful)
2003 HDi 2.2 6-speed Exec Estate (2012-19) (also a gem)
2009 Citroen C5 2.0 HDi VTR+ Estate (godawful heap)
2008 BMW E91 330i touring (great fun - murdered by a reversing SUV)
2007 BMW E91 325i touring (slower smoother quieter)
phil81
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Re: How to: Diesel Particle Filter Removal

Post by phil81 »

Im currently having a nightmare been in limp mode now for 6months :cry: , first anti pollution fault,unblock filter and limp mode then alittle after i got the message telling me the eolys was empty. I've along the way had dodgy mechanics either no idea on faps or thought they did but turns out they didnt, eolys fluid topped up, new fap from the breakers put on still got all the faults and limp mode (think this was because he tried resetting codes not using pp2000)
Just read this the other day and this is my last chance before the car has to go to fleebay. I've smashed out the inside of my old fap and am going to buy the Galletto 1260 tonight.

Doggy if i pm you would please send me the 136 bhp no fap ecu map file?

I've never done anything like this before but here goes hoping as long as i back up the original ecu file on my car now the worst i could do is put it back in the state its in now.
Thanks Phil
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Doggy
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Re: How to: Diesel Particle Filter Removal

Post by Doggy »

Hi Phil & welcome to the forum. 8)

Drop me a PM & I'll see what I can do.
2002 HDi 2.2 Exec Estate, (2008-12) (wonderful)
2003 HDi 2.2 6-speed Exec Estate (2012-19) (also a gem)
2009 Citroen C5 2.0 HDi VTR+ Estate (godawful heap)
2008 BMW E91 330i touring (great fun - murdered by a reversing SUV)
2007 BMW E91 325i touring (slower smoother quieter)
martint
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Re: How to: Diesel Particle Filter Removal

Post by martint »

So ur gonna put a mapped file on ur car that hasnt been tweeked for ur car!
Mate ur better sending ur map off to hdi tuning-£80.
Got mines remapped.great job. He sends it back to u by email for the galletto to do
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OdinEidolon
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Re: How to: Diesel Particle Filter Removal

Post by OdinEidolon »

martint wrote:So ur gonna put a mapped file on ur car that hasnt been tweeked for ur car!
Mate ur better sending ur map off to hdi tuning-£80.
Got mines remapped.great job. He sends it back to u by email for the galletto to do
The same map has been used by tens of HDi owners on this forum, and some other tens on the coupe' forum.
I know it's not nice to know you've wasted money but please don't try to make others pay for a unnecessary map file, when we have a perfectly good one, tried and tested by many many users. If I had to choose, I'd go for something that I know for sure works, that many have tried.
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