Baz Meredith investigates a Ford Tourneo Connect suffering from multiple warning lights, tracing a “blocked” DPF message back to a common wiring fault rather than a failed component.
In his latest video, Baz takes on a Ford Tourneo Connect presented with engine management and ABS warnings.
The vehicle’s instrument cluster displayed a “DPF overloaded” message, but as is often the case with modern diesel diagnostics, the on-screen prompt proved to be a symptom rather than the root cause.
Baz begins the process with a high-speed scan, identifying several stored codes.
While the ABS system showed a front-left wheel speed sensor fault, a test drive with live data monitoring suggested the sensor and pick-up rings were currently functional.
Shifting focus to the DPF, Baz notes fault codes for restriction and, crucially, a high voltage circuit fault on the particulate filter pressure sensor.
Technical investigation revealed that with the engine off, the sensor was reporting a static 80 mbar of pressure.
Suspecting a wiring or sensor failure, Baz noted signs of previous intervention, including a missing heat shield and evidence of work around the oxygen sensor.
He reminds viewers that in the independent trade, technicians often have to act as detectives to piece together the history of a vehicle that has already been “played with” elsewhere.
To verify the state of the DPF, Baz uses a manometer to measure the physical pressure at the exhaust.
The tool confirmed a healthy reading of approximately 8 mbar at idle, proving the filter was not physically restricted.
Further inspection of the harness revealed broken wires at the pressure sensor connector, which Baz repaired by depinning the plug and soldering the connections to restore circuit integrity.
Even with the physical repair complete, the ECU still reported a soot accumulation of 219%, a default fail-safe value triggered because the computer could not previously calculate the pressure.
To resolve this, Baz had to “think outside the box” regarding his diagnostic software.
Finding no reset options under the specific Tourneo profile, he accessed the “special functions” menu through a Ford Focus 1.5 profile to successfully reset the DPF learned values and perform a forced regeneration.
