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DPF Forced Regeneration Issues


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Hi All,

 

This is my first post in this forum at looking for some help regarding DPF.

 

I have a 2008 Octavia vRS 2.0 TDi (CEGA Engine) with just under 190,000kms on the clock.

A couple of weeks ago while driving (without warning) the engine light (MIL) came on followed by the DPF light.

 

When I got home my Bluetooth scan tool revealed the following OBD stored code:

“P2563 – Turbocharger Boost Control Position Sensor Circuit Range”

 

I also read the Owner’s Manual regarding the DPF light and set off on a drive to try and regenerate the DPF as per the instructions.

 

I set off on the Freeway (in 5th Gear) and once set for the trip set the Cruise Control.  5 to 10 minutes in to my trip, the cruise control turned-off and the car went in to “Limp Home mode” (Glow Plug Light started flashing on the dash).  I tried to continue/start the regen process again but nothing happened.

 

Drove the car back home and checked the OBD stored codes and the following code was (in addition) also logged:

“P2002 – Diesel Particulate Filter below Threshold – Bank 1”

 

So I have two issues with the car.

 

1.       Turbo Boost Actuator

2.       DPF

 

Turbo Boost Actuator:-

I diagnosed the Turbo Boost Actuator control to be faulty (split diaphragm) after applying Vacuum (through a hand pump) to the unit, it would not hold pressure.

 

I purchased a new one from my local VW dealer (Repair Kit Part No: 03L 198 716 A) and finally managed to replace it! 

Cleared the error code: “P2563”, started the car MIL gone and went for a drive around the block.  Checked again and this error code has not reappeared.

 

However, the car is still in “Limp Home mode” so next issue was to force the regeneration of the DPF.

 

DPF issues:-

Using VCDS I have tried to force the regeneration without any success.

 

DPF Status (as outputted by VCDS):

 

Address 01: Engine  (03L 906 022 HF)

 

15:41:21 Group 099: Diesel Particle Filter

2300 /min  Engine Speed (G28)

348.0°C  Temperature prior Turbo Charger

     Temperature prior Particle Filter

     Temperature after Particle Filter

 

15:41:21 Group 108: Diesel Particle Filter

78 ml  Particle Filter Oil Ash Volume

50.1  Particle Filter Carbon Mass (spec.)

44.1  Particle Filter Carbon Mass (act.)

      

 

15:41:21 Group 100: Diesel Particle Filter

258.0°C  Temperature prior Precatalytic Converter

246.0°C  Temperature prior Particle Filter

251 mbar  Particle Filter Different. Pressure

 0 mbar  Particle Filter Offset Different. Pressure

 

As mentioned I tried to force the regeneration using VCDS two ways (without any affect)

 

VCDS Method 1 (Security Access):

From the Engine Module:

1.       Click on “Security Access”

2.       Enter Code “12233”

3.       Select “Regeneration while Driving”

4.       Enter “1” as new Value

 

VCDS Method 2 (Coding II):

1.       Click on “Coding II)

2.       Enter Code “21295”

 

Even though the Control modules accepted both codes the temperatures prior to Particle Filter and prior to Precatalytic Converter (Group 100) would not rise to the required temperatures.  Maximum temperature “prior Particle Filter” that I witnessed was 306ºC and even that was a struggle to reach!).

 

So it looks like my car is not performing the Forced Regeneration even through VCDS.

 

My Questions:-

 

  1. I’m guessing it is not performing the Regeneration because the car is “Limp Home mode” therefore, with restricted turbo/performance means the engine cannot dump the extra fuel, etc. to get the DPF hot enough.
  2. Too much carbon built up (even though I am just below 45)?
  3. Measuring Block/Group 099, Temperature prior to and after Particle filters are blank.  I expect some reading to be displayed in VCDS.
  4. Also when trying to perform an Engine Output Test for “Exhaust Pressure Control Valve (J883), I receive the following message: Refused by Control Module, Message 7F 22 22

 

My apologies for the lengthy post, but any help/direction will be greatly appreciated and I’m sure that there will be more questions arise as I try to solve this issue.

 

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Well the ash content seems to be OK, but I think it may be the soot level which is stopping it happening.

I would be interesting to know what 7F 22 22 means, I'm guessing it is a hex code which means something.

Sent from my D5803 using Tapatalk

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Well the ash content seems to be OK, but I think it may be the soot level which is stopping it happening.

I would be interesting to know what 7F 22 22 means, I'm guessing it is a hex code which means something.

Sent from my D5803 using Tapatalk

 

7F2222 is too long for a single diagnostic code as a translation to decimal gives 8331810

 

If the first part of the code is a location then putting 2 and 2 together to make 5 you could say that the code is 1810. This is the unswitched battery voltage low, which can be a corroded terminal etc. As I say, a total guess but might prompt something useful.

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Thanks for responding guys.

 

The 7F 22 22 message is displayed when trying to perform an "Output Test" using VCDS for "Exhaust Pressure Control Valve (J883)".  I have a screen shot of the window but I'm not sure how to link/attach it to this post. :|

 

I'm not sure if the output test has been Refused by the controller because the car is in "Limp Home Mode" due to the DPF?

 

Further investigation continues  :sweat:

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When I had such a problem then I visited a garage.

The guy at first removed the error codes and my car was driveable - limp mode was gone (did you do that?). Then he tried forced regeneration. It couldn't be completed. The software said that turbo temperature wasn't high enough. It was impossible to raise it to the needed level (did some high-rev driving though) but anyway he did the forced regeneration again....unsuccesfully.

Anyway it cleaned that DPF a bit and after a longer drive everthing's fine.

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Looking at your info your soot loading is 44 grams and you should have had warning from 24 grams. From how your indications came up it could be that your G450 differential pressure sensor could be faulty, need to buy a new one and adapt using VCDS before staring the engine again. I have attached a picture which shows when the different indications should be received and at what soot loading.

 

 

 

 

Regen2.bmp

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Thanks again for the replies.

 

I believe that I cannot get the car to the Forced Regeneration because the car is in "Limp Home" mode.

This will not allow the car fuel/exhaust system to get hot enough.

 

I'm not sure what is causing the car to stay in "Limp Home" mode (Even with a "clogged" DPF I am leaning towards the EGR system).

 

 

Looking at your info your soot loading is 44 grams and you should have had warning from 24 grams. From how your indications came up it could be that your G450 differential pressure sensor could be faulty, need to buy a new one and adapt using VCDS before staring the engine again. I have attached a picture which shows when the different indications should be received and at what soot loading.

 

I have seen this chart before and am not sure at what point the DPF warning light came on.  I purchased VCDS cable about week after the DPF light came on (still learning about all of this stuff!).   The G450 Pressure sensor displays 0 mbar with the Ignition ON and Engine OFF (which is what is expected).  If the Pressure Sensor was faulty I would expect to see some other value. Between the DPF and Turbo Boost Actuator, it seems to have been some sort of chain reaction.

 

 

After replacing the Turbo Actuator Boost Control I cleared all of the codes and went for a couple of drives since.  The error code (P2563) relating to the turbo is no longer stored in ECU.  When using VCDS, the voltages readings for this (position) sensor are within range I didn't perform an "Adaption" for this in VCDS.  I'm not sure if an Adaption needs to be done because it seems to be OK now.

 

OUTPUT Tests:-

I do not have any error codes stored relating to EGR.

However, when viewing "Readiness" in VCDS, the Exhaust Gas Recirculation is "Failed or Complete"

There is also an EGR error when performing the "Basic Settings" cycle for EGR through VCDS.

 

I understand the Readiness Codes are set to "Fail or Incomplete" when all DTC's are cleared and that these On-Board Emissions Tests will "Pass" once the car has successfully cycled through them during a driving cycle.

 

Without any error codes stored relating to this, I'm not sure what to exactly look for. :dull:

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It is little bit different question, but do You see from VCDs when the car made regeneration? Or how much was completed at least?

It would be nice if you can share what do you see about the regeneration in vcds.

Thx!

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Def look at the G450 pressure sensor, these are known to fail and cause all sorts of DPF issues, mine went 6 months after getting it and spent most of its time in limp mode!! after replacing the sensor and adapting it I did the forced regen and went for a drive and the temp in the exhaust went up to over 700 degrees and i could see the soot coming down..  Seriously fault or not the sensor is only £50 so replace it before going down the garage route and getting shafted!!

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Firstly, thank you to everybody that has so far replied to my post.  I really appreciate your feedback and assistance.

 

Tonight was supposed to be my moment of truth.

 

I had removed the DPF from the car, cut the DPF open and washed out the ‘soot’ build up from the filter.  After welding the filter back together and placing back in the car I was really hopeful that this was going to fix my issue.  I have photos of this that I would like to share but I don’t know how to link/attach to this reply.

 

I performed the Adaption (Reset the DPF) using VCDS, cleared all of the Fault Codes, started the car and…..DPF light came on as well as the dreaded flashing Glow Plug light.

 

The error code stored in the Engine Control Module was:

 

009263 - Diesel Particulate Filter (Bank 1)

               P242F - 000 - Restricted/Clogged - MIL ON

 

Measuring Block – Group 108 was reading:

0 ml        Particle Filter oil Ash Volume

0              Particle Filter Carbon Mass (spec.)

47.4        Particle Filter Carbon Mass (act.)

 

Obviously, this can’t be right since the DPF has been cleaned.

My next step is to replace the G450 (Pressure Differential) Sensor (even though it still seems to be reading pressure differences as expected).

 

 

However, I am also very curious as to why no Temperature values appear in Measuring Block 099 for Temperature BEFORE and AFTER Particle Filter (MB099.3 and MB099.4)???

 

The temp sensors both seem to be physically working.  Using a Multi-meter, the resistance measured between the terminals (of both sensors) at ambient temperature were very similar (215 mOhms) and the resistance had increased after slightly warming up the engine (as expected).

 

Will see what happens after replacing the G450 sensor.Firstly, thank you to everybody that has so far replied to my post.  I really appreciate your feedback and assistance.

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I have tried the Forced Regeneration with VCDS atleast 3 times but never successful.

I'm pretty sure the reason for this is because the car is in "Limp Home" mode.

Sent from my SM-N910G using Tapatalk

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Well this DPF issue is really starting to do my head in!!!

 

Tonight I replaced the G450 Pressure Differential sensor (also did the Adaption) and still no luck.

The Car is still in "Limp Home" mode and is still measuring a Carbon Mass level of 47.1

 

I believe that the temperature sensors are good but for some reason i can't explain why there is no Temperature displayed for PRIOR and AFTER DPF in Measuring Group 099.

 

Has anybody had this issue before with Measuring Group 099?

Can anybody explain how all of the sensors in the DPF system calculate/measure the Carbon Mass level?

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A garage guy told me that te basic idea is measuring pressures - both before and after DPF. If they are more or less similar than system knows that DPF is empty and exhaust gas goes through freely. If there is some difference then judging to the level of it system considers some DPF to be more or less full of ash. Which sensor does what - sorry, can't tell that.

Seems like you have wasted lots of time (and probably money) and without any particular result. What about simply removing that thing and living happy?

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Hindsight is a wonderful thing but when you had the DPF open instead of cleaning it I would have removed the internals and then had all of the sensors mapped out.

 

Job done.

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Mechanically speaking the DPF is clean and there is no reason for the flow to be restricted. This is evident by the pressure difference reading. With engine ON and on idle the G450 sensor is registering 3mbar difference (almost zero) virtually no difference in pressure.

Hence, no restriction in the DPF.

Even if I removed the core completely there is a good chance that it won't work. After clearing the codes and before turning on the engine, the error code logs quickly with only the ignition ON.

I believe there might be some electrical fault which is tell the car there is still a lot of carbon in the DPF which is physically not possible.

I wouldn't say that I have wasted lots of time or money. All the work has been done at home, I have just been learning a lot on this journey. It has been small steps at a time.

I'm just sharing my journey so that other people can learn from this and maybe somebody out there has been through this and can offer some help.

Sent from my SM-N910G using Tapatalk

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THANKS to the OP for this descriptive problem description whilst I am unable to assist with his issues, I too have had a multitude of DPF problems which have involved me having injectors changed etc all to no avail, I have simply adapted my driving to simply remain in lower gears thus keeping the revs higher and hence exhaust temps higher for longer, this seems to be maintaining a level of status quo for the time being and whilst I still get a lumpy engined drive from time to time it simply means its time to go drive like I stole it for 10 - 15 mins that seems to settle it down again for another 600 to 750 miles subject to town or city driving.... I have read this post with great interest after having so many issues with my PD140 2009 Octi 4x4. which as we all now know the PD was not designed to have a DPF and this is the basic problem, the design !  Skoda/VW/Audi jumped the gun in an effort to become green probably under pressure from the EU boffins.. Anyway thanks again I have enjoyed (if that's the correct term) this post and trust the op does resolve his problems once and for all. As I said I too have been through the flashing lights on the dash, and the limp mode problems but have been fortunate enough for my vcds to clear the codes and permit regen as it should when requested. Hope you manage to reslove your problems soon, I know I have simply wanted to throw a match at it at times.

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There are a number of professional outfits that offer a DPF cleaning service, essentially doing what the OP has done, opening it up and giving it a professional clean, then there are others that take it off and simply stick the nozzle of a jet wash in the end.

 

Unfortunately this doesn't seem to be particularly effective, as reported on here in other threads, it looks to be a short term fix as the DPF quickly stops working again.

 

The only real fixes for an end-of-life DPF is to professionally gut and map it out or replace it completely.

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Final update:

The DPF issue with my car seems to be finally resolved.

I took my car to the local Skoda dealer where they performed an Adaptation and a Regeneration which seems to have fixed it for now.

I'm not sure why this didn't work for me using VCDS.

Sent from my SM-N910G using Tapatalk

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Final update:

The DPF issue with my car seems to be finally resolved.

I took my car to the local Skoda dealer where they performed an Adaptation and a Regeneration which seems to have fixed it for now.

I'm not sure why this didn't work for me using VCDS.

Sent from my SM-N910G using Tapatalk

 

I've heard that dealers have some software that allows more than anything available for simple users. Maybe they had possibility to reset something that's not available for you.

That's strange anyway. I'd understand  that you wouldn't be able to disable airbags by VCDS or so but restarting DPF system should work fine.

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I've heard that dealers have some software that allows more than anything available for simple users. Maybe they had possibility to reset something that's not available for you.

That's strange anyway. I'd understand that you wouldn't be able to disable airbags by VCDS or so but restarting DPF system should work fine.

I don't understand why my VCDS couldn't get the car out of "Limp Home" mode when VCDS and the ECM accepted the Adaptation and Regeneration codes.

Now that it's been done by the dealer I'll conect my VCDS over the weekend to see what the data looks like now.

Thanks again to everybody for your feedback and interest.

Sent from my SM-N910G using Tapatalk

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Do you def have full VCDS or VCDS lite??? when i replaced the G450 sensor on mine a mate with full VCDS did that adaptation and forced regen then I went for a drive to lower the soot content in the DPF and eventually once the content droped below 20% it came out of limp mode... maybe your car still saw the DPF as full regardless of the fact you had it cleaned out.. who knows but I do know that a full version of VCDS will allow you to adapt and perform a forced regen

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Do you def have full VCDS or VCDS lite??? when i replaced the G450 sensor on mine a mate with full VCDS did that adaptation and forced regen then I went for a drive to lower the soot content in the DPF and eventually once the content droped below 20% it came out of limp mode... maybe your car still saw the DPF as full regardless of the fact you had it cleaned out.. who knows but I do know that a full version of VCDS will allow you to adapt and perform a forced regen

It is the full VCDS with a genuine Ross-Tech cable. After Adapting/Resetting the DPF the Ash content and Carbon Mass (spec) went to zero (0) but the car was still measuring Carbon Mass (act. ) as 46.2. I just couldn't get this to drop. I was thinking that there was something funny electrical going on either the ECM or a wire harness issue.

I was expecting after the reset that the car would get out of "Limp Home " mode but it didn't. Every time I cleared the P242F error code it would just come back with only the Ignition ON and Engine OFF.

I knew the sensors were working I just couldn't work out why the car was still measuring a high carbon content in the DPF, hence the trip to the dealer.

The dealer couldn't tell me for certain if the car was in "Limp Home" mode due to the high carbon reading .

Who knows maybe I wasn't doing something right even after following the instructions that I found on the Internet.

Sent from my SM-N910G using Tapatalk

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It is the full VCDS with a genuine Ross-Tech cable. After Adapting/Resetting the DPF the Ash content and Carbon Mass (spec) went to zero (0) but the car was still measuring Carbon Mass (act. ) as 46.2. I just couldn't get this to drop. I was thinking that there was something funny electrical going on either the ECM or a wire harness issue.

I was expecting after the reset that the car would get out of "Limp Home " mode but it didn't. Every time I cleared the P242F error code it would just come back with only the Ignition ON and Engine OFF.

I knew the sensors were working I just couldn't work out why the car was still measuring a high carbon content in the DPF, hence the trip to the dealer.

The dealer couldn't tell me for certain if the car was in "Limp Home" mode due to the high carbon reading .

Who knows maybe I wasn't doing something right even after following the instructions that I found on the Internet.

Sent from my SM-N910G using Tapatalk

 

You def seemed to have missed out on the part where you go for a drive once you have adapted the new sensor... i had to go up and down a bit of dual carriage way for ages as the soot level went down watched live on a laptop by my mate in the passenger seat.. once it dropped below %20 full power came back but i carried on until it was 1% or something silly... never had an issue since and that was over 2 years ago... the drive part is def something you needed to do... im sure i found it on this site telling me to do it...

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