One of the most widespread headaches for owners of Ford Transit and Tourneo Custom 2.2 TDCi Duratorq engines (2012 onwards) is chronic DPF (Diesel Particulate Filter) clogging accompanied by sudden loss of power and the dreaded "Engine Service Now" dashboard alert.
Garages frequently quote upwards of £1,200 to £1,800 to replace the entire DPF unit. However, in over 70% of cases, the DPF itself is completely healthy — the real culprit is a clogged or burnt-out DPF Fuel Vaporiser Sensor Valve (Fuel Doser Injector).
💡 How the Vaporiser Works:
Unlike older systems that squirt raw diesel into cylinders on exhaust strokes, Ford's 2.2 TDCi utilizes a dedicated fuel vaporiser mounted directly inside the exhaust downpipe. It heats diesel with an internal glow plug to over 500°C, triggering DPF passive and active regeneration without diluting engine oil. When its tiny nozzle blocks with carbon, regeneration stops permanently.
Key Symptoms & OBD-II Diagnostic Fault Codes
- Fault Code P244C: Catalyst Temperature Too Low During Regeneration Bank 1 — the vaporiser glow plug has failed or cannot deliver fuel.
- Fault Code P2463: Diesel Particulate Filter – Soot Accumulation — soot levels exceed 85% because regeneration cycles abort.
- Fault Code P246B: Vehicle Conditions Incorrect for DPF Regeneration.
- Vehicle Symptoms: Restricted performance (limp mode), cooling fans running at high speed continuously, high fuel consumption.
Save Over £1,000
DPF Fuel Vaporiser Exhaust Sensor for Ford Tourneo & Transit Custom 2.2 TDCi
OEM Ref: 1774460 / BK21-9T540-AH · Fits 2.2L Duratorq (2012+) · Includes integrated glow plug & heat-shielded harness.
£49.45 · Free UK Delivery
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How to Replace and Restore Regeneration
- Disconnect Battery: Always isolate electrical power before working on glow plug wiring.
- Access Exhaust Downpipe: Raise the vehicle safely on ramps or axle stands. Locate the vaporiser threaded into the exhaust pipe upstream of the DPF canister.
- Disconnect Fuel Line & Connector: Detach the quick-release diesel line (plug it to prevent spillage) and unclip the wiring harness.
- Unscrew the Old Unit: Use a 22mm slotted sensor socket or open-ended spanner. Apply penetrating oil if rusted by heat cycling.
- Install the New BuyDay Vaporiser: Apply high-temperature anti-seize paste to threads (avoid the nozzle tip). Torque to 35 Nm. Reconnect fuel line and wiring.
- Clear Codes & Trigger Static Regen: Connect an OBD scanner, clear the stored P244C/P2463 codes, and command a static DPF regeneration or take a 25-minute motorway run at 2,500 RPM.
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