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FUB-HIL-120010_A10Diesel particle filter service instructions

ISTA system
version

3.52.32.15580

Data version

R3.52

Programming
data

VIN

A302017

Vehicle

3'/E91/SPORTS
WAGON/320d/N47/MANUAL/EUR/LL/2007/11

Integration
level factory

Integration
level (current)

Mileage

0 km

Integration
level (target

Diesel particle filter service instructions

Complaint:
The customer complains about the Check Control message "Diesel particle filter malfunction".
The following fault codes are saved (one or more):
-

480A / 245700 (from F01) DDE: Diesel particle filter - filter is heavily contaminated. (exhaust backpressure is
too high)

481A / 245800 (from F01) DDE: Diesel particle filter - filter is heavily contaminated. (exhaust backpressure is
above maximum)

Cause:
The diesel particle filter is overladen. Regeneration of the diesel particle filter is being prevented by the DDE.
The following cases can arise:
I.

On the 325d and 525d with engine M57TUE:

unfavourable DDE software. The following integration levels are required:
-

325D E89x-09-12-512 or higher

525D E60x-09-12-512 or higher

II.

The diesel particle filter is clogged due the recent driving profile.
Frequent short-distance drives and urban driving cause the diesel particle filter regeneration function to work
less efficiently. Longer, extended and insufficient regeneration triggers the fault entry 480A / 245700 (from
F01). As soon as the fault is saved, regeneration is then no longer possible. This function is inhibited.
If the diesel particle filter does not regenerate itself continuously, and if the exhaust backpressure continues
to rise, the entry 481A / 245800 (from F01) is also made in the fault memory. The Check Control message
"Diesel particle filter malfunction" appears on screen.

III.

Engine fault
-

other additional engine faults are also present

Measure:
I.

On the 325d and the 525d M57TUE:

-

Ensure that the vehicle is programmed with the following integration levels, otherwise update the
integration level:
325D E89x-09-12-512 or higher

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525D E60x-09-12-512 or higher

II.

Perform a vehicle test and all relevant procedures. In the DDE, no relevant fault codes are allowed to be
saved to memory, with the exception of 480A / 245700 (from F01) and 481A / 245800 (from F01). First
correct the existing faults.
Relevant fault codes are faults from the following areas:
-

Charge air system

Exhaust system

Sensors (exhaust backpressure sensor, exhaust-gas temperature sensor)

NOTE: it is possible that the customer, in the light of the Check Control message, may visit the workshop
and that the system may already have regenerated itself (e.g.: through an extended motorway journey). The
customer is now aware of this process occurring. Check if the status of the fault is set to "Currently not
present", then clear the fault memory.
III.

Distance driven since last successful regeneration

IV.

Carry out the procedures for fault codes 480A / 245700 (from F01) and 481A / 245800 (from F01), carry out
the exhaust emissions check and keep a record of the exhaust backpressure figures.

V.

Request regeneration using the service function.

NOTE: Regeneration is blocked by fault codes 480A / 245700 (from F01) and 481A / 245800 (from F01).
Regeneration does not take place until the faults have been rectified by an extended regeneration drive
(refer to chapter on regeneration)

VI.

Carry out a regeneration drive

Once faults 480A / 245700 (from F01) and 481A / 245800 (from F01) have been saved, drive the vehicle for
about 45 minutes at a constant speed. In addition, switch on electrical consumers to keep the exhaust-gas
temperature between 280-350C. That enables continuous regeneration to take place, the exhaust
backpressure drops, the faults are remedied and the following status message is issued: "currently not
present". Now, normal regeneration takes place automatically.

VII.

Establish the distance driven since the last regeneration and check to find out if periodic regeneration has
taken place. This status message is used to confirm successful regeneration.

VIII.

Carry out another exhaust backpressure test with the diagnosis system. The exhaust backpressure must
match the nominal values. If it does not, carry out the following checks:
-

check the charge air system

1.

check pipe connections for leak tightness

2.

check charge air hose for tightness (leaks)

3.

perform air mass system test

4.

carry out function check of swirl flaps and exhaust-gas recirculation valve

Check exhaust emission system:

1.

Check exhaust backpressure hose to diesel particle filter for tightness and damage

2.

Check exhaust sensors: check plausibility of temperature sensors and check the exhaust
backpressure sensor

Regeneration
There are two kinds of regeneration:
1.

Continuous regeneration:
This form of regeneration takes place during normal driving. At exhaust-gas temperatures of between 280350C, continuous regeneration takes place in the form of a slow oxidation process. The soot particles
cannot be incinerated until the exhaust gases reach the required temperature.

2.

Periodic regeneration:
Periodic regeneration is performed automatically by the DDE after no later than 100km (600 miles). On

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vehicles with many short-distance drives, periodic regeneration already starts taking place after just 400800 km (250- 500 miles).
For regeneration, the intake air is reduced by the throttle valve. One or two post-injections are performed.
This increases the exhaust-gas temperature to about 600C. The soot is incinerated with the residual
oxygen.
The periodic regeneration is performed at all speeds. The most efficient method is regeneration at a
constant speed in excess of 60km/h (38mph) over a period of 20-30 minutes.
The DDE calculates the time for periodic regeneration from the following values:
-

average distance travelled

average driving speed

temperature in the diesel particle filter

values from the exhaust backpressure sensor

The last successful regeneration can be read out by the diagnosis system
The following conditions must be fulfilled for a regeneration:
-

the engine temperatur must be in excess of 75C

the exhaust-gas temperature before the diesel particle filter must be greater than 240C

there must be enough fuel (fuel reserve lamp does not light up). Whenever the reserve lamp lights up, the
regeneration process is suspended.

No fault codes from the air system, exhaust emission system and sensors must be saved in the DDE

The fault codes 480A / 245700 (from F01) and 481A / 245800 (from F01) must display the status "currently
not present"

Constant driving speed above about 60km/h (approx. 38mph). The optimum speed is about 100km/h
(approx. 60mph).