Ford EcoBlue 2.0 P2002/P02EC/P049B Diagnostic and Repair Guide

  

This article applies to Ford EcoBlue 2.0 engines equipped with fuel injectors bearing the following part numbers: GK2Q-9K545-AA/AB/AC/AD / FINIS:2143478, regardless of output rating.

Continental P/N: A2C9303500080
Other Possible part number:  RMGK2Q-9K546-AC, 2011879, 2143478, A2C9303500080, GK2Q9K546AB, GK2Q9K546AC, FB3Q9B395AD, FB3Z9A543A, GK2Q-9K546-AD, RMGK2Q-9K546-AB, GK2Q9K546AD, 1881202, 2675955, 2802002051380, FB3Q9B395AB, 

Symptoms and Progression

Early Stage - Primarily affects high-output (190PS) dual EGR systems (e.g., Mondeo/Focus/Kuga EcoBlue 2.0 190PS).

These engines feature a dual EGR emission control, with the low-pressure EGR circuit located downstream of the DPF/SCR system and fitted with a filter before entering the intake manifold.

At this stage, the filter captures carbon particulates produced by suboptimal combustion due to faulty injectors, leading to EGR filter blockage and triggering fault codes such as P02EC and P049B.

If the filter shows a light grayish-white residue, this is likely a urea deposit from excessive AdBlue injection (see Ford TSB 21-2135). Simply replace it with the updated filter (part no. HG9Q-9V473-AB).

If the filter is covered in fine black powder, this indicates the early-stage injector-related issue described in this article.

light grayish-white residue, replace the filter gasket with the latest version

Filled with fine black powder, the early stage of the symptom

I had my filter-gasket filled with black powder around 20k KM, and keeps occurring with fewer and fewer mileage intervals.

Note: Once removed, the filter and its O-ring must be replaced to prevent air leaks and diesel exhaust odor into the cabin through the cabin air intake for the AC.

Mid Stage

After the initial phase, the system may intermittently log P2002 fault codes. Key observations:

1. The check engine light (MIL) may turn on and off, typically extinguishing after two or three starts following a DPF regeneration but reappearing after 100–200 km of driving.
2. DPF regeneration intervals become longer, extending from the normal 150–250 km up to 400 km.
3. When reading fault codes, P2002:00-XX appears, where XX ≤ 7E does not illuminate the warning light, but XX ≥ 80 does. (XX = hexadecimal numbers) No other codes are present at this stage. 
   Ref: Ford TSB:
   http://www.msc.club.tw/FORD_TSB/Ford_TSB_23-7006.pdf
   http://www.msc.club.tw/FORD_TSB/Ford_TSB_23-7072.pdf
   http://www.msc.club.tw/FORD_TSB/GSB.TSB-23-7144-DPF-P2002-Status.pdf
   http://www.msc.club.tw/FORD_TSB/GSB.TSB-23-7142-DPF-Debug.pdf
4. EGR filter blockage recurs more frequently.
5. At high speed/low RPM, the injection quantity is higher than at low speed/low RPM, making P2002 more likely.
6. AdBlue consumption increases from about 0.125L/100km to 0.175L/100km or more.
7. Occasional shift shock and a muffled engine sound may occur.

Late Stage

At this point, the check engine light is almost always illuminated. Multiple variants of the P2002 code appear, and the filter may still be packed with fine black powder and codes P02EC/P049B.

Symptoms include increased shift shock and weak low-end torque, though high-speed driving remains unaffected.

Temporary Fixes / Costly-workaround

Some workshops may replace only the DPF/AdBlue-SCR assembly at this stage. However, if the faulty injectors are not replaced simultaneously, the issue will recur after approximately 3,000 km.
(the author ran into this and has an article for this, in Taiwanese/Chinese: Link)

Root Cause

According to Ford TSB-20-2335, the only effective solution is to replace both the injectors and the DPF. Merely replacing the DPF will lead to recurrence, indicating that the injectors are the primary cause.

Reports from international owners and media confirm that the Continental (formerly Siemens VDO) injectors used in EcoBlue engines may suffer from defective internal coatings, leading to corrosion and failure. This has been documented by owners in Australia and Denmark, as well as by UK automotive media, which have reported flaking of the internal coating causing injector malfunction.
(ref: https://www.youtube.com/watch?v=ki_R-UHbwFA)
(ref: https://www.parkers.co.uk/vans-pickups/news/2019/ford-ecoblue-diesel-injector-failure/)

Additionally, Ford Taiwan has indicated that the use of diesel additives may exacerbate this issue. Owners are advised not to use any diesel additives in EcoBlue engines.(ref: https://blog.mlai.idv.tw/2024/07/vs.html in Taiwanese/Chinese)

Possible Technical Background...

I'd like to explain why this is happening in a more detailed way. However, these sections are without references and are solely my Speculation. Readers may skip this part as this is not directly related to the fixing processes.

Why do faulty injectors cause DPF warning lights and not always affect drivability?

Euro 6.2d diesel vehicles, in addition to DPF and AdBlue SCR systems, are equipped with a particulate matter (PM) sensor before the rear silencer. This sensor detects soot (black smoke) in the exhaust. If persistent soot is detected, the system triggers a P2002 code, indicating "Diesel Particulate Filter Efficiency Below Threshold."

When the injector's internal coating flakes off, the debris can clog the DPF's soot-trapping surface, reducing its effectiveness. The PM sensor then detects increased soot emissions, triggering the warning.

Consequences include:

• Lower the exhaust pressure-difference, so high-speed drivability is unaffected.
• Reduced pressure-difference leads the PCM to delay regeneration, extending intervals up to 400 km.
• Abnormal pressure-difference readings cause low-speed shift shock similar to EGR leaks, as the RPM control is no longer by design where the transmission may release the clutch at the wrong RPM.
• The system compensates by injecting more AdBlue, increasing consumption to try to have the car "cleaner".
• Injector tip clogging increases injection pressure and reduces fuel delivery, raising idle fuel consumption in hot weather with AC on. The EcoBlue idle fuel consumation can be as low as 0.6L/h, but now it's at least 0.8 to 0.9L/h.

Roles of Diesel Additives played here

Most diesel additives contain a lot of detergents. This speeds up the decomposition of the coating inside the injector.

Recommended Solution

If your vehicle exhibits these symptoms:

In the early stage, replace the filter and avoid all diesel additives. As there is nothing you can do, cross your fingers and hope it's a one-time issue.

In the mid-to-late stages, have a trusted diesel injection specialist test your injectors. If faulty, replace both the injectors and DPF simultaneously to prevent premature DPF failure.

If you have already replaced the DPF once and the issue recurred, ensure the injectors are tested before replacing the DPF again. Repeated replacements are costly and unnecessary if the root cause is not addressed.

A faulty injector test result with P2002.

Here is a faulty injector test result with P2002.

Final Note

The author’s own vehicle experienced the entire process described above. After replacing both the injectors and the second DPF, the car has been trouble-free for over 12,000 km, with no further fault codes.

I hope this article can help any owner of an EcoBlue 2.0 engine, allowing them not through the path I have been through.

English is not my native language, and the translation has been processed by the ChatGPT/Perplexity, and reviewed by my eye. Please let me know if you believe there is anything cthat an be improved or to be corrected.