Solution to DPF/FAP problems in diesel engines

Common symptoms of DPF problems

The DPF The Diesel Particulate Filter (known as FAP in PSA Group engines) is a critical component whose problems fill workshops every day. Workshops receive vehicles with... DPF problems in very specific scenarios:

• clogged filter after predominantly urban use that prevents reaching the autonomous regeneration temperature.
• Continuous regeneration cycles which increase consumption and dilute the engine oil.
• Filter melted or damaged due to repeated interrupted regenerations.
• Recurring entry into emergency mode (limp home) due to loss of communication with the DP sensors.
• Recurring DTCs: P2002, P2452, P2453, P244A, P244B, P2463, P2458, P246F and OEM variants.
• Unaffordable replacement costAn original filter can cost between €1,500 and €3,500.

Our approach: comprehensive system recalibration

When a workshop sends us a file with DPF problems, we intervene by recalibrating the ECU to normalize engine operation and correct the symptoms. The recalibration works on:

• The active and passive regeneration algorithm of the filter.
• The logic for reading upstream and downstream differential pressure sensors.
• The target values of temperature sensors T3, T4 and T5.
• Post-combustion injection designed to raise the exhaust temperature.
• The estimation of accumulated soot mass and regeneration counters.
• The diagnosis of related DTCs.
• The recalculation of checksum for internal ECU validation.

The result is a vehicle that stops entering regeneration cycles, recovers normal accelerator response, and reports no issues related to the filter.

ECU compatibility

We work with all diesel ECU families from the European, Asian, and American markets:

Typical applications of this service

• Workshop repair: vehicles with a physically damaged filter where replacement is not economically viable.
• Agricultural and industrial machinery: tractors, harvesters, forklifts, generator sets where the filter has no operational purpose.
• Off-road use: 4x4 vehicles, extreme modifications, driving in dusty environments.
• Competition: rally vehicles, trials, closed circuit.
• Export: vehicles intended for markets without equivalent anti-pollution regulations.

Technical process

1. The workshop sends the original file extracted with a professional tool (KESS, K-TAG, Autotuner, CMD Flash, FlexBox…).
2. We identified the exact ECU family and software version.
3. We applied the corresponding recalibration, validated critical maps, and adjusted the checksum.
4. We return the modified file ready to flash. Typical delivery in under 30 minutes.

If you need more details about the workflow with our service, please refer to the Quick service guide. For common errors when remapping, see the guide to ECU remapping errors.

Advantages over solutions with emulator hardware

• No additional modulesThere is no extra wiring that can fail or become disconnected.
• Consistent OBD readingThe ECU does not report any DTCs related to the filter.
• Improved engine responseTorque restrictions are avoided during regeneration attempts.
• Lower consumption in the city: since regeneration cycles do not occur, urban consumption is noticeably reduced.
• ReversibleWe always keep the original file so we can restore the factory software if needed.