Ford Kuga 163 2.0 tdci Diesel Particulate Filter [DPF] faulty sensor. P2020, P2456, P246C, P2463, P246B

Funny coincidence after the flat battery or maybe as a consequence of jump starting the car but almost as soon as the car was running there was  engine malfunction on the dash followed by EML light and limp home mode.
Even resetting codes and long runs didn't help.

I tried diagnostics but it wasn't until 2 days running I got some useful codes indicating a sensor problem

Interestingly the first few codes it threw were P2020, diesel particulate filter efficiency below threshold bank 1. But a few runs and clearing gave me the ones below........

These were

Code: P2452 - Diesel Particulate Filter Differential Pressure Sensor Circuit

Code: P2456 - Diesel Particulate Filter Differential Pressure Sensor Circuit Intermittent/Erratic

Code: P246C - Diesel Particulate Filter Restriction - Forced Limited Power

Code: P2463 - Diesel Particulate Filter - Soot Accumulation

Code: P246B - Vehicle Conditions Incorrect for Diesel Particulate Filter Regeneration

The actual output from ForScan is below and very helpful

===DTC P246C:00-AF===
Code: P246C - Diesel Particulate Filter Restriction - Forced Limited Power

Status: 
- DTC Present at Time of Request
- Malfunction Indicator Lamp is On for this DTC

Module: Powertrain Control Module===END DTC P246C:00-AF===

===DTC P2463:97-AF===
Code: P2463 - Diesel Particulate Filter - Soot Accumulation

Additional Fault Symptom:
- Component Or System Operation Obstructed Or Blocked

Status: 
- DTC Present at Time of Request
- Malfunction Indicator Lamp is On for this DTC

Module: Powertrain Control Module

Diagnostic Trouble Code details

If DTCs P242F and P244B are set, do not perform the diesel particulate filter static regeneration. Investigate these DTCs first.

It is important to determine the root cause of the blocked filter.

Note: The following procedure must be performed exactly as instructed.
Re-program the PCM to the latest level calibration.
Engine Warm Up
Use Datalogger to check the following:
Engine coolant temperature
Engine temperature must reach 80 degrees celsius
Perform the following powertrain service function:
Reset the Diesel Particulate Filter Learned Values
Perform the following powertrain service function:
Diesel Particulate Filter Static Regeneration
Investigate any other DTC that may be present in order to determine the root cause.

This DTC may be caused by :
EGR valve stuck in the open position.
Leakage, blockage or restriction in air intake system.
Air leak in the vacuum hoses between the turbocharger and the air intake throttle.
Blocked or leaking differential pressure sensor hoses.
Differential pressure sensor electrical fault.
Pre-catalyst temperature sensor electrical fault
Post-catalyst temperature sensor electrical fault
===END DTC P2463:97-AF===


===DTC P246B:97-2F===
Code: P246B - Vehicle Conditions Incorrect for Diesel Particulate Filter Regeneration

Additional Fault Symptom:
- Component Or System Operation Obstructed Or Blocked

Status: 
- DTC Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Powertrain Control Module===END DTC P246B:97-2F===

===DTC P2452:97-2F===
Code: P2452 - Diesel Particulate Filter Differential Pressure Sensor Circuit

Additional Fault Symptom:
- Component Or System Operation Obstructed Or Blocked

Status: 
- DTC Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC
Module: Powertrain Control Module
Diagnostic Trouble Code details
signal open circuit, shorted to VPWR or ground
Signal out of range
===END DTC P2452:97-2F===

===DTC P2456:92-2C===
Code: P2456 - Diesel Particulate Filter Differential Pressure Sensor Circuit Intermittent/Erratic

Additional Fault Symptom:
- Performance Or Incorrect Operation

Status: 
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Powertrain Control Module
Diagnostic Trouble Code details
This DTC may be caused by :

An intermittent open or short circuit
Sensor Previously disconnected.
Differential pressure sensor
Damaged or contaminated connector
Damaged connector pins 

Visually inspect the PCM connector and wires as far back as the main loom for damage and corrosion. Repair or clean as appropriate
===END DTC P2456:92-2C===

===DTC P2463-C===
Code: P2463 - Diesel Particulate Filter - Soot Accumulation
Status: 
- Confirmed - mailfunction is confirmed 
Module: On Board Diagnostic II===END DTC P2463-C===

Fearful of doing permanent damage to the dpf and a plausable reason for issues I took the car to a local garage to sort, service was faultless.

http://www.ashcroftautocentre.co.uk/

New sensor.  
Static regen and voila its back. 
Only time will tell if it stays this way.

Total cost was £197 (diagnosis, new sensor, fitting and static regen)


ELM 427 cable to support MS and HS CAN is here
Black USB Modified ELM327 Elmconfig Forscan Ford Focus Mondeo Kuga S-Max http://r.ebay.com/KwyuOL


Kuga forum has a very useful thread here on all Kuga Mk1 related DPF issues

http://www.kugaownersclub.co.uk/forum/all-mk1-engine-management-dpf-issues-info_topic5726.html