Ongoing DPF issues - is genuine VW part the answer?

[JJ Blue]

2007 California Ocean here with 159k. We cannot get to the bottom of this problem hoping that someone here can give input please:-

DPF needed investigation last November because warning lights were coming on. Our regular mechanic recommended taking it to a specialist garage for DPF cleaning. The garage told us that the DPF was completely shot and was therefore uncleanable. New aftermarket part was put on. Warning lights (coil light flashing, DPF, engine management) came on again within 20 miles of leaving the garage despite them telling us they had done all the usual checks, regens etc. Took the vehicle back to garage who replaced the new DPF in case it was faulty. Same thing happened again. Various re-gens and code clearing have been done. Test runs show that the re-gens are happening but the filter very quickly returns to 80% full. Warning lights stay off for around 40 miles and then come on again.

Some mechanics have advised that a genuine VW DPF (many £££s) is going to be the only solution or could it be something to do with the electronics simply not liking the DPF that was put on? Or perhaps the DPF is actually OK and its something else?

We would welcome thoughts and input please.

 

[Wish]

Have you changed all relevant sensors?

 

[JJ Blue]

Yes we've replaced sensors.

 

[Lambeth Cali]

Can I just ask did the van ever go into limp mode? Massive noticeable loss of power.

I have to agree with the above. Sounds like sensors and also perhaps never was the DPF.

A few years ago I drove around for 18months with the engine light on because my VW specialist was certain we had a faulty DPF sensor. Part 076906051A for 2008 T5 - mine.

I plugged in a £40 code reader and did a bit of Googling. Eventually I bought the sensor off eBay and fitted myself. Then had to plug my wife’s laptop in and set adaptation using a free Ross-Tech 'VCDS Lite' download to make it work. Copied a YouTube video on how to do this. All fixed. I’m no mechanic.

These sensors have crystals in them to measure pressure changes. Not sure I would have fitted an aftermarket DPF as very unlikely to ever marry to a VW sensor.

I would Google VW DPF sensors and buy a code reader off Amazon that will tell you exactly what the fault is rather than this usual mechanic “let’s just change lots of parts”.

THERE ARE A LOT OF DPF SHARKS OUT THERE. Possibly a £18 sensor. Get a code reader. V v useful. Unless the van is going into limp mode, I doubt the DPF is the fault....

Replacing and adapting the Exhaust Pressure Sensor

I have a 2008 T5 174 California and have replaced the G450 exhaust pressure sensor (076906051A) and adapted it using VCDS Lite. 2 years ago the engine light came on in our Cali. My VW specialist garage told me the error code suggested it was the exhaust pressure sensor and that as the van was...

vwcaliforniaclub.com

https://www.amazon.co.uk/ANCEL-Diagnostic-Volkswagen-Diagnosis-Throttle/dp/B07BS7PDC2/ref=asc_df_B07BS7PDC2?mcid=8cd35886effd3d7ca95f13caa960e8c9&tag=googshopuk-21&linkCode=df0&hvadid=697250304661&hvpos=&hvnetw=g&hvrand=6154262561034992964&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9045943&hvtargid=pla-471775458400&gad_source=1&th=1

 

[JJ Blue]

Thank you for all the info - very much appreciated.
Yes, the vehicle is now in limp mode.
There was a new DPF pressure sensor (same part number as your one) fitted last year when we had intermittent warning lights coming on. However the lights came back on again, so at this point our mechanic recommended the DPF might need to be cleaned. Took it to the specialists who installed the new aftermarket DPF together with two other sensors.
Could the problem relate to the fact that we have one VW genuine sensor and two non-VW sensors in place, all trying to communicate with an aftermarket DPF?
I have absolutely no mechanical knowledge so just trying to think logically/laterally

 

[JJ Blue]

Can I just ask did the van ever go into limp mode? Massive noticeable loss of power.

I have to agree with the above. Sounds like sensors and also perhaps never was the DPF.

A few years ago I drove around for 18months with the engine light on because my VW specialist was certain we had a faulty DPF sensor. Part 076906051A for 2008 T5 - mine.

I plugged in a £40 code reader and did a bit of Googling. Eventually I bought the sensor off eBay and fitted myself. Then had to plug my wife’s laptop in and set adaptation using a free Ross-Tech 'VCDS Lite' download to make it work. Copied a YouTube video on how to do this. All fixed. I’m no mechanic.

These sensors have crystals in them to measure pressure changes. Not sure I would have fitted an aftermarket DPF as very unlikely to ever marry to a VW sensor.

I would Google VW DPF sensors and buy a code reader off Amazon that will tell you exactly what the fault is rather than this usual mechanic “let’s just change lots of parts”.

THERE ARE A LOT OF DPF SHARKS OUT THERE. Possibly a £18 sensor. Get a code reader. V v useful. Unless the van is going into limp mode, I doubt the DPF is the fault....

Replacing and adapting the Exhaust Pressure Sensor

I have a 2008 T5 174 California and have replaced the G450 exhaust pressure sensor (076906051A) and adapted it using VCDS Lite. 2 years ago the engine light came on in our Cali. My VW specialist garage told me the error code suggested it was the exhaust pressure sensor and that as the van was...

vwcaliforniaclub.com

https://www.amazon.co.uk/ANCEL-Diagnostic-Volkswagen-Diagnosis-Throttle/dp/B07BS7PDC2/ref=asc_df_B07BS7PDC2?mcid=8cd35886effd3d7ca95f13caa960e8c9&tag=googshopuk-21&linkCode=df0&hvadid=697250304661&hvpos=&hvnetw=g&hvrand=6154262561034992964&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9045943&hvtargid=pla-471775458400&gad_source=1&th=1

When a code reader is used (our one and the garage ones) it flags up 'DPF' as the issue. But the DPF was replaced.

 

[Lambeth Cali]

I never do anything mechanical normally but a sensor seemed doable.

If it’s in limp mode then DPF does seem probable. Do you have a picture of what the code reader says? There are so many T4/5 forums Googling specific codes can find stuff. I thought mine spat out an error/fault number.

I would hope others might chime in.

I struggle to see an aftermarket DPF working with VW sensors.

 

[Louis II]

Understand the points about sensors etc but given the fact that the original DPF was clogged beyond repair and the new one seemingly clogs very quickly, clears through regen then clogs again have you considered possible causes of excess soot from the engine? Eg issues with injectors, turbo hoses etc. Is there any visible black smoke from the exhaust? I had a Mazda with failed DPF caused by something to do with the injectors. I had the injectors fixed and the DPF removed but I think that’s illegal now

 

[TripleBee]

Does the EGR return valve stay open perhaps?
When driving with a new DPF, did you feel less power?
Did you have any other driving experience that indeed lead to failing injector(s)?

 

[Wish]

We went through a similar problem with our Volvo XC60… sorted/ not sorted/ sorted / France (amber engine light), called for help… a local mechanic bought out tow truck… but now light off. Rest of trip fine got back to UK engine light back on. Independent garage… DPF off and soaked DPF in cleaner… mechanic scratched his head & said you’ll have to take it to Volvo… he couldn’t think of anything else other than a software issue… got to Volvo… the problem was (apparently) on a recall (but only when a customer bought in there car to the dealership)… the solution was to adapt and replace the hose system around the DPF absolutely fine thereafter… The one occasion I’d wish I’d used the dealership from the start & saved a lot of money , time and angst…

 

[californiakid]

We went through a similar problem with our Volvo XC60… sorted/ not sorted/ sorted / France (amber engine light), called for help… a local mechanic bought out tow truck… but now light off. Rest of trip fine got back to UK engine light back on. Independent garage… DPF off and soaked DPF in cleaner… mechanic scratched his head & said you’ll have to take it to Volvo… he couldn’t think of anything else other than a software issue… got to Volvo… the problem was (apparently) on a recall (but only when a customer bought in there car to the dealership)… the solution was to adapt and replace the hose system around the DPF absolutely fine thereafter… The one occasion I’d wish I’d used the dealership from the start & saved a lot of money , time and angst…

Check O'Riley on Youtube as he's an expert on DPF'S and as he says if you do not fix the fault first you will have on going issues as you are experiencing .

 

[Wish]

Check O'Riley on Youtube as he's an expert on DPF'S and as he says if you do not fix the fault first you will have on going issues as you are experiencing .

We have had no problems since… but a tad annoying when Volvo choose not to release the TSS recall (oh and by the way)… anyway, just one more angle to consider…

 

[Dorchest]

I’ve just had the exact same problem with my 2007 California. Kept going into limp mode and engine warning light coming on. I needed to use the vehicle so lived with it for a while until I started smelling exhaust fumes inside the vehicle.

Took it to my long term garage and have just paid 3K (ouch!) to have it fixed including a service and MOT. Replacement DPF (after service part but with warranty as apparently, a new one imported from Germany would have been 4K +VAT which I don’t think is sensible for a vehicle this age). New turbo. There were still warning lights on after doing the work so new DPF pressure sensor, Lambda sensor and Temperature sensor fitted which resolved that issue. Just did a 240 mile return trip straight after getting it back and seems to be running really well.

See the parts list attached from my invoice. How much did the work you had done cost?

Mike J

 

[JJ Blue]

Thank you for your input Mike, it's really helpful. I will reply fully this evening once my husband has had a look at your info. We've already spent a fair bit having the aftermarket DPF fitted. Will check my invoices...

 

[JJ Blue]

Understand the points about sensors etc but given the fact that the original DPF was clogged beyond repair and the new one seemingly clogs very quickly, clears through regen then clogs again have you considered possible causes of excess soot from the engine? Eg issues with injectors, turbo hoses etc. Is there any visible black smoke from the exhaust? I had a Mazda with failed DPF caused by something to do with the injectors. I had the injectors fixed and the DPF removed but I think that’s illegal now

Thank you Louis. Useful info.
We're planning to get the injectors and EGR valve checked to see if that is the problem. Wish we'd never put the aftermarket DPF on, but we were frightened by the price of the genuine VW one! Plus we were still smarting from having had the camshaft replaced!

 

[JJ Blue]

We went through a similar problem with our Volvo XC60… sorted/ not sorted/ sorted / France (amber engine light), called for help… a local mechanic bought out tow truck… but now light off. Rest of trip fine got back to UK engine light back on. Independent garage… DPF off and soaked DPF in cleaner… mechanic scratched his head & said you’ll have to take it to Volvo… he couldn’t think of anything else other than a software issue… got to Volvo… the problem was (apparently) on a recall (but only when a customer bought in there car to the dealership)… the solution was to adapt and replace the hose system around the DPF absolutely fine thereafter… The one occasion I’d wish I’d used the dealership from the start & saved a lot of money , time and angst…

Thank you for this info - it's all very useful.

 

[JJ Blue]

Thank you for your input Mike, it's really helpful. I will reply fully this evening once my husband has had a look at your info. We've already spent a fair bit having the aftermarket DPF fitted. Will check my invoices...

I’ve just had the exact same problem with my 2007 California. Kept going into limp mode and engine warning light coming on. I needed to use the vehicle so lived with it for a while until I started smelling exhaust fumes inside the vehicle.

Took it to my long term garage and have just paid 3K (ouch!) to have it fixed including a service and MOT. Replacement DPF (after service part but with warranty as apparently, a new one imported from Germany would have been 4K +VAT which I don’t think is sensible for a vehicle this age). New turbo. There were still warning lights on after doing the work so new DPF pressure sensor, Lambda sensor and Temperature sensor fitted which resolved that issue. Just did a 240 mile return trip straight after getting it back and seems to be running really well.

See the parts list attached from my invoice. How much did the work you had done cost?

Mike J

View attachment 135443

First bill for the DPF to be removed, found to be breaking up, replaced with aftermarket one (£478) + two sensors (£162 each) came to just over £1300
Second bill to determine that the DPF was working OK, new hose, DPF cleaner = £335
Third bill to diagnose fault codes, install genuine VW DPF pressure sensor = £170
Fourth bill to carry out DPF reset and regen = £180

And still the warning lights are on!
Going to check the EGR valve and injectors next...

 

[JJ Blue]

Does the EGR return valve stay open perhaps?
When driving with a new DPF, did you feel less power?
Did you have any other driving experience that indeed lead to failing injector(s)?

Thank you for your input.
We're going to get the EGR valve and the injectors checked next week.
I don't recall any loss of power after the new DPF was fitted, but I honestly can't remember. That was back in November. I was more concerned about the lights coming back on again just 20 miles after leaving the garage
The van only went into limp mode about three weeks ago.
Re your final question - I'm not sure about having a driving experience that indicated failing injectors. What might that have felt like?

 

[JJ Blue]

Check O'Riley on Youtube as he's an expert on DPF'S and as he says if you do not fix the fault first you will have on going issues as you are experiencing .

Binge watching O'Riley now. Thank you for this info!

 

[TripleBee]

Thank you for your input.
We're going to get the EGR valve and the injectors checked next week.
I don't recall any loss of power after the new DPF was fitted, but I honestly can't remember. That was back in November. I was more concerned about the lights coming back on again just 20 miles after leaving the garage
The van only went into limp mode about three weeks ago.
Re your final question - I'm not sure about having a driving experience that indicated failing injectors. What might that have felt like?

Bad starting. Hiccups when asking a lot of power, or just on asking low power.
Does your engine burn oil?
Do you use the right oil? If you have the R5 engine, you need special oil for that engine. It has to meet the VW 506.01 standards.