Fuel Vapour Valves

Articles

What is a Fuel Vapour Valve?

A Fuel Vapour Valve (FVV) is an electronically heated glow plug situated before the catalytic converter in the exhaust gas stream. The FVV functions by evaporating the diesel fuel and Particulate Matter (PM), and then injecting it into the exhaust gas stream directly before the Diesel Particulate Filter (DPF). The main purpose of the FVV is to improve the regeneration process of the DPF and lower harmful emissions from the exhaust system.

Without the use of FVVs, traditional fuel systems raised the issue that when unburned/ unevaporated diesel was injected into the combustion chamber for the catalyst to raise the temperature, this was causing oil dilution, engine wear, and an increased need to service vehicles.

Now, with FVVs, fuel can be evaporated before it reaches the combustion chamber, meaning vapourised fuel can then be burned by the catalytic converter to raise the temperature before the DPF. This means that fuel regeneration conditions can be optimised, without the need of additional cooling, which decreases the risk of oil dilution.

 

 

Emissions Legislations

Due to current emissions standards in Europe and the USA, it is now a requirement for the use of DPFs. The 1992 European Union Regulations were created with the aim to improve air quality, and the implementation of the 2009 EURO 5 Emissions Standards mean that DPFs are now mandatory. Research has shown that DPFs capture approximately 99% of all particulate matter, and cars that meet the EURO 6 Emissions Standards emit the equivalent of one grain of sand of particulate matter per kilometre driven.

An FVV is a critical component pre-DPF for improved fuel regeneration conditions.

 

Why is a Fuel Vapour Valve important?

The functionalities of an FVV can provide many benefits as an FVV:

  • Avoids oil dilution, meaning engine breakdowns and the increase in need for oil service may be reduced, as well as an improvement of fuel economy and the decrease in harmful emissions
  • Does not require additional cooling and requires less mixing length when compared to an injector
  • Enables more frequent DPF regeneration with low load conditions and when idling to allow an extended operating range
  • Does not require specialist tools for fitting, only a potential bleed of the valve when refitted with a fluid container to collect any excess diesel and an ammeter
  • Is designed to eliminate clogging
  • Provides efficient diesel distribution and low back pressure

 

Diagnosing a Faulty Fuel Vapour Valve

If an FVV fails, DPF regeneration can be compromised to the point that it stops functioning. Typically, in this case, this may:

  • Illuminate the ‘Engine Management’ light on a vehicle’s dashboard, or
  • Display a service message recognising the fault
  • Cause poor driveability

 

How to Change Fuel Vapour Valve*

  1. Underneath the front of the vehicle, there will be a bracket/ panel secured with bolts. Unscrew the bolts to remove the panel and put to one side.

 

  1. Locate the FVV.

 

  1. Locate the Union Nut and unscrew it. Sometimes, the Nut will be rusted and so an open-ended spanner may not be able to loosen. In this case, some layers of WD-40 could be sprayed onto the Nut and left to sit. Heat may be applied to attempt to loosen. If heat does not work in loosening/ removing the Nut, a saw, such as a reciprocating saw, could be used to cut the Main Body away from the Nut. Once cut, a handle wrench could be used to loosen the Nut.
    • When working around heat and fuels, it is always recommended to have a fire extinguisher available in case of fire.

 

  1. Once the Nut is loosened, remove the FVV, or, if cut, also remove the FVV’s Nozzle from the exhaust.

 

  1. When removed, you will be able to see the Nozzle clogged with particulate matter. The FVV will not be able to be used again, therefore it should be disposed of.

 

  1. When fitting the new FVV, there will be a notch on the Nozzle which needs to be aligned when fixing into the exhaust. When aligned, the Nozzle will ‘drop’ into the exhaust.

 

  1. Tighten the Nut by hand and tighten further using a spanner/ wrench.

 

  1. Feed the fuel lines along and attach the Electrical Connection back up.

 

  1. Re-screw the bracket/ panel.

 

  1. Before the vehicle is used, it is recommended that the FVV is tested via a diagnostic system to ensure correct functioning.

 

*Do not attempt if unsure and, instead, contact a garage for professional replacement.

 

Fuel Vapour Valves available at Merlin Diesel Systems Ltd

Merlin’s online shop holds the following FVVs – click the images below to be directed to the corresponding Merlin shop page:

 

FORD FUEL VAPOUR VALVE: 1548748 / 8C11-9T540-BA – TRANSIT

M002-072

Part Number Vehicle Fitment Engine Variant Additional Information Price
  • Ford FINIS: 1548748
  • Ford Engineering: 8C11-9T540-BA
Transit 2.4L/ 3.2L:

  • Ford Transit 2.4 TDCi 4X4 Box
  • Ford Transit 2.4 TDCi 4X4 Bus
  • Ford Transit 2.4 TDCi 4X4 Platform
  • Ford Transit 2.4 TDCi Bus
  • Ford Transit 2.4 TDCi RWD Box
  • Ford Transit 2.4 TDCi RWD Platform
  • Ford Transit 3.2 TDCi Bus
  • Ford Transit 3.2 TDCi RWD Box
  • Ford Transit 3.2 TDCi RWD Platform
  • Ford Transit TDCi RWD Box
2.4 / 3.2 2000-2016
  • SKU: M002-072
  • OEMS: Ford 1548748, 8C11-9T540-BA

Ex Tax:

£104.29

 

Inc Tax:

£125.15

 

FORD FUEL VAPOUR VALVE 1856982 / AV61-9T540-BF

M002-076

Part Number Vehicle Fitment Engine Variant Additional Information Price
  • Ford FINIS: 1856982
  • Ford Engineering: AV61-9T540-BF
  • Ford Galaxy 2.0L/2.2L
  • Ford Mondeo 2.0L/2.2L
  • Ford S-Max 2.0L/2.2L
  • Ford Galaxy 2.0 TDCi MPV
  • Ford Galaxy 2.2 TDCi MPV
  • Ford Mondeo 2.0 TDCi Hatchback
  • Ford Mondeo 2.2 TDCi Hatchback
  • Ford Mondeo Turnier 2.0 TDCi Estate
  • Ford Mondeo Turnier 2.2 TDCi Estate
  • Ford S-Max 2.0 TDCi MPV
  • Ford S-Max 2.2 TDCi MPV
2.0 / 2.2 2006-2015
  • SKU: M002-076
  • OEMS: FORD AV61-9T540-BF, FORD 1856982

Ex Tax:

£102.91

 

Inc Tax:

£123.49

 

FORD FUEL VAPOUR VALVE: 1860939 / AV41-9T540-BD

M002-075

Part Number Vehicle Fitment Engine Variant Additional Information Price
  • Ford FINIS: 1860939
  • Ford Engineering: AV41-9T540-BD
Kuga I 2.0L:

  • Ford Kuga I 2.0 TDCi 4X4 SUV
  • Ford Kuga I 2.0 TDCi SUV
2.0 2008-2012
  • SKU: M002-075
  • OEMS: FORD AV41-9T540-BD, FORD 1860939

Ex Tax:

£108.85

 

Inc Tax:

£130.62

 

FORD FUEL VAPOUR VALVE: 1877097 / CV61-9T540-AB

M002-083

Part Number Vehicle Fitment Engine Variant Additional Information Price
  • Ford FINIS: 1877097
  • Ford Engineering: CV61-9T540-AB
Mondeo V 2.0L:

  • Ford Kuga 2.0 TDCi 4X4 SUV
  • Ford Kuga 2.0 TDCi SUV
2.0 2013-2018
  • SKU: M002-083
  • OEMS: FORD CV61-9T540-AB, FORD 1877097

Ex Tax:

£104.47

 

Inc Tax:

£125.36

 

FORD FUEL VAPOUR VALVE: 1877192 / CC11-9T540-BG

M002-081

Part Number Vehicle Fitment Engine Variant Additional Information Price
  • Ford FINIS: 1877192
  • Ford Engineering: CC11-9T540-BG
Transit 2.2L:

  • Ford Transit 2.2 TDCi Box
  • Ford Transit 2.2 TDCi Bus
  • Ford Transit 2.2 TDCi Platform
2.2 2006-2014
  • SKU: M002-081
  • OEMS: FORD CC11-9T540-BG, FORD 1877192

Ex Tax:

£106.63

 

Inc Tax:

£127.96

 

FORD FUEL VAPOUR VALVE: 1879927 / CV6Q-9T540-AG

M002-084

Part Number Vehicle Fitment Engine Variant Additional Information Price
  • Ford FINIS:1879927
  • Ford Engineering: CV6Q-9T540-AG
Ford Focus 1.6L:

  • Focus 1.6 TDCi Econetic Hatchback
  • Focus 1.6 TDCi Saloon
  • Focus Turnier 1.6 TDCi Econetic Estate
1.6 2012-2018
  • SKU: M002-084
  • OEMS: FORD CV6Q-9T540-AG, FORD 1879927

Ex Tax:

£128.43

 

Inc Tax:

£154.12

 

FORD FUEL VAPOUR VALVE: 1890231 / E1G1-9T540-AD

M002-085

Part Number Vehicle Fitment Engine Variant Additional Information Price
  • Ford FINIS: 1890231
  • Ford Engineering: E1G1-9T540-AD
Mondeo V 2.0L:

  • Ford Mondeo V 2.0 TDCi 4X4 Hatchback
  • Ford Mondeo V 2.0 TDCi 4X4 Saloon
  • Ford Mondeo V 2.0 TDCi BiTurbo Hatchback
  • Ford Mondeo V 2.0 TDCi Hatchback
  • Ford Mondeo V 2.0 TDCi Saloon
  • Ford Mondeo V Turnier 2.0 TDCi 4X4 Estate
  • Ford Mondeo V Turnier 2.0 TDCi BiTurbo Estate
  • Ford Mondeo V Turnier 2.0 TDCi Estate

S-Max 2.0L:

  • Ford S-Max 2.0 TDCi 4X4 MPV
  • Ford S-Max 2.0 TDCi BiTurbo MPV
  • Ford S-Max 2.0 TDCi MPV
2.0 2015-2019
  • SKU: M002-085
  • OEMS: FORD E1G1-9T540-AD, FORD 1890231

Ex Tax:

£160.40

 

Inc Tax:

£192.48

 

FORD FUEL VAPOUR VALVE: 1902014 / FV41-9T540-BB

M002-086

Part Number Vehicle Fitment Engine Variant Additional Information Price
  • Ford FINIS: 1902014
  • Ford Engineering: FV41-9T540-BB
Focus 2.0L:

  • Ford Focus 2.0 TDCi Hatchback
  • Ford Focus 2.0 TDCi ST Hatchback
  • Ford Focus 2.0 TDCi Saloon
  • Ford Focus Turnier 2.0 TDCi Estate
  • Ford Focus Turnier 2.0 TDCi ST Estate

Kuga II 2.0L:

  • Ford Kuga 2.0 TDCi 4X4 SUV
  • Ford Kuga 2.0 TDCi SUV
2.0 2014-2018
  • SKU: M002-086
  • OEMS: FORD FINIS 1902014, FORD 8C11-9T540-BA

Ex Tax:

£113.98

 

Inc Tax:

£136.78

 

FORD FUEL VAPOUR VALVE: 1940310 / BK21-9T540-AH

M002-077

Part Number Vehicle Fitment Engine Variant Additional Information Price
  • Ford FINIS: 1940310
  • Ford Engineering: BK21-9T540-AH
Transit Custom 2.2L:

  • Ford Transit Custom 2.2 TDCi Bus

Transit Tourneo 2.2L:

  • Ford Transit Tourneo 2.2 TDCi Bus
2.2 2006-2019
  • SKU: M002-077
  • OEMS: FORD BK21-9T540-AH, FORD 1940310

Ex Tax:

£111.20

 

Inc Tax:

£133.44

 

FORD FUEL VAPOUR VALVE: 1940313 / BK31-9T540-BG

M002-079

Part Number Vehicle Fitment Engine Variant Additional Information Price
  • Ford FINIS: 1940313
  • Ford Engineering: BK31-9T540-BG
Transit 2.2L:

  • Ford Transit 2.2 TDCi 4X4 Box
  • Ford Transit 2.2 TDCi 4X4 Bus
  • Ford Transit 2.2 TDCi 4X4 Platform
  • Ford Transit 2.2 TDCi Box
  • Ford Transit 2.2 TDCi Bus
  • Ford Transit 2.2 TDCi Platform
  • Ford Transit 2.2 TDCi RWD Box
  • Ford Transit 2.2 TDCi RWD Bus
  • Ford Transit 2.2 TDCi RWD Platform
2.2 2013-2018
  • SKU: M002-079
  • OEMS: FORD BK31-9T540-BG, FORD 1940313

Ex Tax:

£138.06

 

Inc Tax:

£165.67

 

FORD FUEL VAPOUR VALVE: 2009096 / AB39-9T540-AF

M002-074

Part Number Vehicle Fitment Engine Variant Additional Information Price
  • Ford FINIS: 2009096
  • Ford Engineering: AB39-9T540-AF
Ranger 2.2L/ 2.3L:

  • Ford Ranger 2.2 TDCi 4X4 Pickup
  • Ford Ranger 2.2 TDCi Pickup
  • Ford Ranger 3.2 TDCi 4X4 Pickup
2.2 / 2.3 / 3.2 2011-2018
  • SKU: M002-074
  • OEMS: FORD AB39-9T540-AF, FORD 2009096

Ex Tax:

£112.09

 

Inc Tax:

£134.51

 

Ford Fuel Vapour Valve: 2022247 / CC11-9T540-BG – TRANSIT

M002-082

Part Number Vehicle Fitment Engine Variant Additional Information Price
  • Ford FINIS: 2022247
  • Ford Engineering: CC11-9T540-BG
Transit 2.2L:

  • Transit 2.2 TDCi 4X4 Box
  • Transit 2.2 TDCi 4X4 Platform
  • Transit 2.2 TDCi RWD Box
  • Transit 2.2 TDCi RWD Bus
  • Transit 2.2 TDCi RWD Platform
2.2 2011-2014
  • SKU: M002-082
  • OEMS: FORD CC11-9T540-BG, FORD 2022247

Ex Tax:

£83.77

 

Inc Tax:

£100.52

 

FORD FUEL VAPOUR VALVE: 2039911 / BK31-9T540-AG

M002-078

Part Number Vehicle Fitment Engine Variant Additional Information Price
  • Ford FINIS: 2039911
  • Ford Engineering: BK31-9T540-AG
Transit 2.2L:

  • Ford Transit 2.2 TDCi 4X4 Box
  • Ford Transit 2.2 TDCi 4X4 Bus
  • Ford Transit 2.2 TDCi 4X4 Platform
  • Ford Transit 2.2 TDCi AWD Bus
  • Ford Transit 2.2 TDCi RWD 4X4 Bus
  • Ford Transit 2.2 TDCi RWD 4X4 Platform
  • Ford Transit 2.2 TDCi RWD Box
  • Ford Transit 2.2 TDCi RWD Bus
  • Ford Transit 2.2 TDCi RWD Platform
2.2 2011-2019
  • SKU: M002-078
  • OEMS: FORD BK31-9T540-AG, FORD 2039911

Ex Tax:

£112.90

 

Inc Tax:

£135.48

 

FORD FUEL VAPOUR VALVE: 2167210 / BK31-9T540-CA

M002-080

Part Number Vehicle Fitment Engine Variant Additional Information Price
  • Ford FINIS: 2167210
  • Ford Engineering: BK31-9T540-CA
Transit 2.2L:

  • Ford Transit 2.2 TDCi 4X4 Box
  • Ford Transit 2.2 TDCi 4X4 Bus
  • Ford Transit 2.2 TDCi 4X4 Platform
  • Ford Transit 2.2 TDCi Box
  • Ford Transit 2.2 TDCi Bus
  • Ford Transit 2.2 TDCi Platform
  • Ford Transit 2.2 TDCi RWD Box
  • Ford Transit 2.2 TDCi RWD Bus
  • Ford Transit 2.2 TDCi RWD Platform
2.2 2013-2018
  • SKU: M002-080
  • OEMS: FORD BK31-9T540-CA, FORD 2167210

Ex Tax:

£144.70

 

Inc Tax:

£173.64

 

FORD FUEL VAPOUR VALVE: 5312744 / 9T16-9T540-AF

M002-073

Part Number Vehicle Fitment Engine Variant Additional Information Price
  • Ford FINIS: 5312744
  • Ford Engineering: 9T16-9T540-AF
Mondeo V 2.0L:

  • Ford Transit Connect 1.8 Di Box
  • Ford Transit Connect 1.8 TDCi Box
1.8 / 2.0 2002-2013
  • SKU: M002-073
  • OEMS: FORD 9T16-9T540-AF, FORD 5312744

Ex Tax:

£149.96

 

Inc Tax:

£179.95

 

MERCEDES BENZ ADBLUE INJECTOR – VAPOUR VALVE: A0004900200

M002-094

Part Number Vehicle Fitment Engine Variant Additional Information Price
  • Sprinter (W907) 2018 onwards
  • 211 CDI
  • 214 CDI
  • 311 CDI
  • 314 CDI
  • 316 CDI
  • 319 CDI
  • 411 CDI
  • 414 CDI
  • 416 CDI
  • 419 CDI
  • 514 CDI
  • 516 CDI
  • 519 CDI
2.2 2018 onwards
  • SKU: M002-094
  • OEMS: No

Ex Tax:

£112.09

 

Inc Tax:

£134.51

 

PSA GROUP ADBLUE INJECTOR – VAPOUR VALVE: 98 027 638 80/G048B03134

M002-093

Part Number Vehicle Fitment Engine Variant Additional Information Price
  • 6 Blue HDi (2015-2020)
Citroen:

  • C3, C4
  • DS3, DS4, DS5
  • Jumpy
  • Dispatch
  • Berlingo
  • C-Elysee

Peugeot:

  • 208
  • 301
  • 308
  • 508
  • 2008
  • 3008
  • 5008
  • Expert
  • Partner
1.6 2015-2020
  • SKU: M002-093
  • OEMS: PSA Group 98 027 638 80 / G048B03134

Ex Tax:

£170.03

 

Inc Tax:

£204.04

 

 

FOR MORE INFORMATION ON OUR FUEL VAPOUR VALVES, PLEASE VISIT OR CONTACT:

 

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