
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
- 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.
- Locate the FVV.
- 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.
- Once the Nut is loosened, remove the FVV, or, if cut, also remove the FVV’s Nozzle from the exhaust.
- 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.
- 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.
- Tighten the Nut by hand and tighten further using a spanner/ wrench.
- Feed the fuel lines along and attach the Electrical Connection back up.
- Re-screw the bracket/ panel.
- 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 |
| Transit 2.4L/ 3.2L:
| 2.4 / 3.2 | 2000-2016 |
| 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 |
|
| 2.0 / 2.2 | 2006-2015 |
| 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 |
| Kuga I 2.0L:
| 2.0 | 2008-2012 |
| 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 |
| Mondeo V 2.0L:
| 2.0 | 2013-2018 |
| 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 |
| Transit 2.2L:
| 2.2 | 2006-2014 |
| 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 Focus 1.6L:
| 1.6 | 2012-2018 |
| 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 |
| Mondeo V 2.0L:
S-Max 2.0L:
| 2.0 | 2015-2019 |
| 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 |
| Focus 2.0L:
Kuga II 2.0L:
| 2.0 | 2014-2018 |
| 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 |
| Transit Custom 2.2L:
Transit Tourneo 2.2L:
| 2.2 | 2006-2019 |
| 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 |
| Transit 2.2L:
| 2.2 | 2013-2018 |
| 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 |
| Ranger 2.2L/ 2.3L:
| 2.2 / 2.3 / 3.2 | 2011-2018 |
| 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 |
| Transit 2.2L:
| 2.2 | 2011-2014 |
| 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 |
| Transit 2.2L:
| 2.2 | 2011-2019 |
| 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 |
| Transit 2.2L:
| 2.2 | 2013-2018 |
| 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 |
| Mondeo V 2.0L:
| 1.8 / 2.0 | 2002-2013 |
| 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 |
|
| 2.2 | 2018 onwards |
| 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 |
| Citroen:
Peugeot:
| 1.6 | 2015-2020 |
| Ex Tax: £170.03
Inc Tax: £204.04 |
FOR MORE INFORMATION ON OUR FUEL VAPOUR VALVES, PLEASE VISIT OR CONTACT:
- Website: www.merlindiesel.com
- Telephone: +44 (0) 1772 694130
- Email: [email protected]
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