How TO: Diesel Particle Filter Removal- The Final Solution?

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Doggy
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How TO: Diesel Particle Filter Removal- The Final Solution?

Post by Doggy »

I really like my 2.2 HDi but have dreaded the seemingly inevitable wallet-draining FAP related problems that must eventually come.

Attack being the best form of defence, I decided to do something about it before I was forced into expensive service / repair work.

The diesel particle filter, ('DPF' or 'FAP'), requires cleaning or replacement periodically, (typically 50k, but varies wildly according to driving conditions), the Eolys additive aslo 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. :shock:

The system is as shown below:
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Item 11 is the CAT c/w downpipe & flexy section: 12 is the DPF

On the car, it looks like this:

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

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

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

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and MUCH lighter.

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)?

I was expecting to get error messages / engine management light due to the lack of differential pressure across the CAT / FAP unit and have a plan for that also, (know of a remap place that can remove / disable the ECU functions related to this system). To my surprise, this didn't happen - so until it does, I won't bother having it done :D

I didn't go into this lightly, I've trawled through all of the available info, (the 406 coupe forum is currently about the richest source), both before & since buying the car. I was also experiencing the dreaded 'ANTIPOLLUTION FAULT' regularly. In the last 3 months of 2009, it went from fortnightly to every 2nd day, each episode involving a journey in limp mode. Left to go on, I believed it must end with a blocked FAP and steep bill very soon, so I decided to avoid it if possible.

I have also disconnected the wiring to the Eolys additive pump, whle leaving the level sensor connected. It doesn't need the additive as there's no FAP to block and I understand it's nasty stuff, so don't want to emit the fumes for no reason. Once I'm certain ther's no downside, I'll remove the additive tank too.

I'm very pleased with the results so far - engine is smoother, more powerful, has a wider effective rev range - I'm taking some corners a gear higher and it now pulls well to nearly 4000, where it previously ran out of breath at about 3500. Fuel consumption has improved slightly and may get better when I get over the novelty :oops:
There's an increase in exhuast noise, but only really noticeable from inside the cabin, when stationary.
At the time of writing, the car's done about 750 miles since FAP removal, so it's early days, but I'm convinced I've done the right thing 8)


A BIG thank you to jasper5, who arranged all of the above work & MOT for me :D
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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Welly
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Re: How TO: Diesel Particle Filter Removal- The Final Solution?

Post by Welly »

WOW :shock:

So, like, you just smashed the filter out leaving an empty cannister? the restriction of that filter must have been huge.

It kinda seems then that the FAP system is stand-alone really and once the ECU asks for some additive then it leaves the rest to physics/chemistry and almost assumes that its done its job :? the only safe guard being the FAP d/p sensor which can't sense a blockage now in yours as it probably thinks the filter is brand new and free-flowing :oops:

Nice one Doggy, and a thumbs-up to Jasper too! nice member co-ordination there 8)
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StevieboyTD
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Re: How TO: Diesel Particle Filter Removal- The Final Solution?

Post by StevieboyTD »

Heh, did the same thing on the wifes 306 a couple of days ago.

Taking advantage of the exhaust snapping behind the cat on our 2 week old dturbo, i though i'd make the most of the situation and decat it while i was doing the repair to the exhaust.

Most obvious idea would be to fit the straight through pipe from a ph1 that i've got in my goodies pile. Which is at the workshop. Which is closed on a Sunday. :mad:

So, i read through various threads, cut it open, dig it out, weld it up or beat it with a spike, or hammer a broom handle through it, etc, etc.

These all sound like too much hassle to me.

I want something simple, something easy to do, something that needs very little in the way of actual "work" on my part.





































Like sticking an 18" masonry drill bit through the lot of it and pouring it our like a milkshake :D

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Yes, i am easily amused ;)
2.1td exec estate.
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mjb
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Re: How TO: Diesel Particle Filter Removal- The Final Solution?

Post by mjb »

Great job - sent to the KB!

If you want it plugged into a PP2000 to see what the ECU has to say about all this (and reset your eolys indicator :lol:), you're more than welcome to pay a visit to Stoke.
<steve_earwig> I think this forum is more about keeping our cars going with minimal outlay than giving our cars more reason to go bang
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Doggy
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Re: How TO: Diesel Particle Filter Removal- The Final Solution?

Post by Doggy »

mjb wrote:Great job - sent to the KB!

If you want it plugged into a PP2000 to see what the ECU has to say about all this (and reset your eolys indicator :lol:), you're more than welcome to pay a visit to Stoke.
Might well take you up on that offer sometime Matt - I'll start saving for some Stella 8)
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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waue1978
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Re: How TO: Diesel Particle Filter Removal- The Final Solution?

Post by waue1978 »

Is it also worth removing any wiring that may be going to the filler flap? I'm sure I've read somewhere about the control for the Eolys injection being linked to that & also that the ecu doesn't detect how much is in the tank, it calculates when the tank would be empty from how many times the Eolys is added (or in your case how many times the ecu thinks Eolys is being added).

Other than that, I'm chuffed somebody has finally found a solution to what has been a bloody nightmare for a lot of HDi owners.

Just wish I'd hung on now for a 2.2HDi & done that myself rather than getting my 110. Had a C5 2.2Hdi a few years ago & the power delivery was brilliant. It just wasn't worth all the hassle I was getting from the bloddy FAP filter!
2000/X Peugeot 406 110 HDi LX Family 93k to 2000/W BMW 530D SE Auto 84k to 2003/03 Peugeot Partner Hdi Escapade 98k to 2003/53 Vauxhall Zafira DTi Elegance 74k

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Doggy
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Re: How TO: Diesel Particle Filter Removal- The Final Solution?

Post by Doggy »

You're right about the flap switch triggering the addition of Eolys to the fuel tank, so I suppose making it think the flap's permanently shut might delay the onset of DIESEL ADDITIVE LOW - this is based on the quantity of additive it believes has been injected. There's a level sensor in there too, (a thermistor which is reputed to burn out if left uncovered for prolonged periods). :roll:

Thanks for the suggestion, if I can locate the connections & determine the correct state for filler cap on, I'll disconnect or bridge-out as necessary.

Welcome to the club BTW 8)
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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waue1978
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Re: How TO: Diesel Particle Filter Removal- The Final Solution?

Post by waue1978 »

Thanks for the welcome. Only bought my 110 Estate recently, but it's the 4th 406 that I've owned - had a 96 1.8LX & 2 99 2.0GLX Saloons previously. Bought it to replace our Mondeo TDDi estate as we wanted something with the 7 seat option. Had been looking at 307 SWs, but the 90s felt gutless & all the others have the dreaded FAP! Originally intended to spend up to £3k on a late SE or an Executive then fit the extra seats, but found this one for £1500 with them already fitted. Its an X plate with 78k so due an expensive cambelt/pulley/water pump change this year, but even that leaves it working out cheaper than I'd originally intended.
Only gripes I've got are that the CD player won't play my CDRs (tried cleaning, but just can't seem to get to the lens) & it doesn't have the feel like it has the grunt that the Mondeo had, even though the power outputs are similar. Have noticed that the Pug has fairly tall gearing & a bit less torque (189lb/ft as opposed to the Mondeo's 206lb/ft). Economy not as good either - was getting 39mpg average from the Mondeo & Pug only showing about 32mpg on the computer. Still like it though.
2000/X Peugeot 406 110 HDi LX Family 93k to 2000/W BMW 530D SE Auto 84k to 2003/03 Peugeot Partner Hdi Escapade 98k to 2003/53 Vauxhall Zafira DTi Elegance 74k

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Re: How TO: Diesel Particle Filter Removal- The Final Solution?

Post by Captain Jack »

32mpg? Ouch... Is the car fully loaded all the time?
2003 - 2008: 1998 Peugeot 406 2.1 TD 110bhp LX Saloon
2008 - 2009: 2004 Honda Accord 2.2 CDTI 136bhp Executive Saloon
2009 - 2013: 2002 Peugeot 406 2.0 HDI 110bhp Executive Saloon
2013 - 2021: 2007 Peugeot 407 2.2 HDI 170bhp Executive Saloon (mapped to 213bhp :twisted:)
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waue1978
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Re: How TO: Diesel Particle Filter Removal- The Final Solution?

Post by waue1978 »

Usually just me & the little man, but that average also takes into account that it's mainly short trips. But we did do a trip from Andover to Boscombe last weekend & only really averaged 40ish (kept resetting the computer to see what it was doing just on a long run). Haven't filled it up yet to do a proper calculation, but did read somewhere on here that sometimes the computer can under-read by about 5mpg so I'm hoping it's that. Had a quick check to see if there were any split hoses anywhere under the bonnet & all looks ok & never leaves any puddles under the car. Half considering getting a tuning box as they seem to go for about £100, but ideally want to wait till the cambelt's been changed so I don't damage anything. Also need to bear in mind that I'm on the original clutch & more power usually shortens the life of that!
2000/X Peugeot 406 110 HDi LX Family 93k to 2000/W BMW 530D SE Auto 84k to 2003/03 Peugeot Partner Hdi Escapade 98k to 2003/53 Vauxhall Zafira DTi Elegance 74k

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BruceT
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Re: How TO: Diesel Particle Filter Removal- The Final Solution?

Post by BruceT »

Sorry to thread highjack but 32mpg is plain wrong.

My 406 (90HDi)

I used it for short commute to work (2.5 miles one way) in stop start traffic twice a day. The engine doesnt get warm, the needles doesnt even move.

THe traffic is terrible I can get (Driving normal, nothing super economical) 33-36mpg on the info centre thing, real world (on my MPG spreadsheet) its actually doing 36-38mpg over the last 4 months.

I think there is something wrong with your car for it to be that short.

My misses wagon with the 35kg dog, weeks luggage and her not so light foot we can get 49-54mpg on the motorway over 200 miles.
His: 1990 Volkswagen Golf II 1.8 GTi 8v.
Hers: 2000 "W" 406 Estate GLX HDi 90 (Bosch) @ 150k
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