I've read everything I can on this, and come up with no exact same problem. Mondeo, Mk4 2.0 tdci, 133000 miles
Here's a summary: drove home from France on saturday (about 550 miles, mainly fast motorway). No problems.
Monday morning, started car and drove to work. When the car got to normal temp, I got a "blocked diesel filter" message, and a minute or two later a "engine malfunction" message.
I took this to mean that the car had tried to do a regen on the DPF, but couldn't, for some reason.
It's done the same thing each time I've driven it monday and today.
We hooked it up to a friends diagnostic computer this evening, and fault codes showed blocked dpf. Pressure differential across DPF with engine running of 2.1 kPa. Pressure differential with ignition on, but engine off, 0.0 kPa.
We cleared the fault codes, tried a forced regen, which seemed to spend 20 mins doing nothing. We again cleared the fault codes, and switched off. On restarting, same errors.
Now, here's the puzzling bit. We stopped the engine, and cleared all the error codes. Turned the ignition on, and the "blocked diesel filter" message popped up again. Now, my question is - how can the car have detected a full DPF with the engine off ? No pressure differential across the DPF, surely the car doesn't know it needs a regen, until the engine is running.
So, do we suspect a faulty differential pressure sensor ?
( I can't see how it can be the hoses, as with the engine not running, they should both be at atmospheric pressure, and indeed the readings showed 0.0 kPa differential...)
Advice please ? Do I shell out on a new sensor and see if that cures it ?