I've searched the forums and, whilst there's useful information regarding DPF regeneration and where to obtain aftermarket replacement DPFs, I'm wondering if anyone has any experience of actually replacing one.

 

The exhaust on my 2011 estate, approximately 122k miles on the clock, started blowing and, thinking it was most likely the back box or middle pipe, took it into the local ATS yesterday to see about getting either or both replaced. Turned out it was a fairly major split in the pipe leading from the engine side of the DPF to the flexi pipe; which they also stated was on its way out.

 

Was quoted £1100 for replacement, by ATS, with the local dealer quoting nearly £1400. After sitting down and recovering from the shock I dug out the Haynes Manual and had a look at what exactly is involved in replacing this part, before looking online for alternative suppliers.

 

I've been quoted anything between £88 + VAT and delivery - £600, both new and salvaged, but if it's too complex to replace, or the aftermarket units don't match the OEM parts, I might be forced to either arrange for a local garage to fit the an aftermarket unit or bite the bullet and go with the ATS quote.

 

I've patched up the exhaust at the moment, using a steel bandage and paste, just to stop the thing coming apart, but need to look at getting it sorted, so any advice or experience would be most appreciated.

I think you might struggle to do this at home. The DPF is buried at the back of the engine. Not an easy job to do on a driveway in my opinion.

 

Useful reading here: https://www.briskoda.net/forums/topic/451684-16-tdi-cr-bunch-of-problems-inc-dpf/

Thanks. 

 

TBH, I was looking at purchasing the aftermarket part and looking to see if a local garage can do the replacement; just the mention of the need to lower the subframe makes it a bit impractical for a home mechanic, but it's trying to figure out whether this is a practical alternative to paying the £1100 at ATS (the dealer price is just for the part, which sounds to be refurbished, as you have to do a like for like swap with the old one).

 

I'm wondering how many hours labour we'd be looking at, on top of buying the replacement, as it's normally this that pushed up prices for repairs into the, "I need to go and sit down in a dark room", category.

Speak to your local garage, and see what they would do and more importantly what they would fit. Suspect they'll need VCDS to clear codes once the new unit is fitted. It's 2011, 122k miles, so I wouldn't be looking for new. Also, I'd be looking for a cleaned and tested DPF, not something that's come from a salvaged car with no history.

 

Incidentally, be careful of ordering anything from breakeryard.com. 

 

 

Darkside could make you one with a DPF for less than that...

Thanks again.

 

Looking at local garages though, typically, I have to pick a bank holiday weekend, when they're all only open for 1 of the 4 days I'm off shift at work to be hunting around.

 

Sorry AMD87, you've lost me with Darkside. I take it that's the username of a member of the site.

 

As even the replacement from the dealer's will be a refurbished unit, I'm looking at going down the aftermarket route anyway, though, even with these the variations in prices are huge; anywhere from £88 + VAT and delivery to nearly £600; the latter does at least include the installation kit, with all the gaskets, clamps, etc.

 

Thankfully, the bandage should hold it together until I can get the repair sorted, and there's no warning lights on the dash, so it shouldn't go into limp mode.

 

TBH. I think it's a brilliant little car and, as the exhaust is 8 years old, I suppose it had to go at some point. Just a shame it had to be the most expensive part that went first. Makes you wonder if you're getting payback for having crept into a church and done something unmentionable on the altar, in a previous life

 

2 minutes ago, GlenP said:

Thanks again.

 

Looking at local garages though, typically, I have to pick a bank holiday weekend, when they're all only open for 1 of the 4 days I'm off shift at work to be hunting around.

 

Sorry AMD87, you've lost me with Darkside. I take it that's the username of a member of the site.

 

As even the replacement from the dealer's will be a refurbished unit, I'm looking at going down the aftermarket route anyway, though, even with these the variations in prices are huge; anywhere from £88 + VAT and delivery to nearly £600; the latter does at least include the installation kit, with all the gaskets, clamps, etc.

 

Thankfully, the bandage should hold it together until I can get the repair sorted, and there's no warning lights on the dash, so it shouldn't go into limp mode.

 

TBH. I think it's a brilliant little car and, as the exhaust is 8 years old, I suppose it had to go at some point. Just a shame it had to be the most expensive part that went first. Makes you wonder if you're getting payback for having crept into a church and done something unmentionable on the altar, in a previous life

 

www.darksidedevelopments.co.uk

Keep us posted. I'm watching this thread with interest. I patched my exhaust with a metal sleeve and gasket compound a few months back before the catalytic converter section as it came up as an advisory at MOT it was blowing. My car is 98k miles on a 10 plate.

I'll keep you posted, but I've just had a look at this Workshop Manual diagram: https://workshop-manuals.com/skoda/fabia-mk2/power_unit/1.6/55;_66;_77_kw_tdi_cr_engine/exhaust_system/removing_and_installing_parts_of_the_exhaust_system/pre-exhaust_pipe_with_diesel_particle_filter_vehicles_with_right-hand_drive_summary_of_components/

 

and it's actually snapped just before, what I'm assuming to be, a second CAT (Octavia exhaust system diagram indicates this could be the NO2 CAT), at the lower end of the downpipe; they've also stated the flex pipe is on its way out, but the fact the manual identifies the DPF as not being what they state it is has me worried.

 

Edited 20 April, 20197 yr by GlenP
Further info found

Interesting link. 

 

I didnt realise they classed the DPF as the first cat. That sounds remarkably like the same location as mine. Put it like this, it should be possible extract the DPF, downpipe and flexijoint and get the damn thing welded, if the DPF has started to rupture that's a different story. Trouble with ATS and the like, they lack the skills to repair, opting for fitting new, when in theory this could last another 5-6 years welded up?

 

The second skin on my back box dropped off about 2 years ago. It's still running!

 

If you put it to a main Skoda dealer they'll video the whole thing and bill you a minimum of £120 for the privilege. I go back to my original point, search out a trusted VAG independent garage, tell them what you know and if it's fixable without incurring quite frankly rediculous costs of £1,400 and the like.

Latest update. 

 

Managed to get the car into a local garage, this morning.

 

They were hoping they could just weld in a replacement section of pipe but, because the flexi pipe has also failed, and the configuration of the DFP and first catalytic convertor, they're instead going to whip the assembly off the car and cut the flexi pipe, etc., off the car, cut it off above the flexi pipe and weld a new flexi pipe onto the downpipe. (Don't know as yet how they're going to connect in the NO2 cat.

 

Have to drop it off on the way home from work, Thursday night and leave it so they can give all of Friday and Saturday morning to the job. Quoted price is, " A couple of hundred quid".

 

Has the advantage that there should be no need to map the DPF in using VAGCOM.

 

Will update further once the work is done.

Good news.

 

Would you believe it. My car exhaust has started leaking near the catalytic converter. I'd patched it before, but looks like I'll need to get under it again tomorrow to investigate.

Update. Great day for working under a car! Stripped out the catalytic converter. Turns out it's sheared just where it joins the flexi exhaust pipe from the DPF. Used an angle grinder to cut the exhaust clamps at the join at the back of the catalytic converter to the middle exhaust pipe. Disconnect sensor 4 and two control hoses to differential pressure sender and disconnect at hangers.

 

Managed to insert a length of 50mm exhaust pipe into the catalytic converter, clamp it on with exhaust gum and seal with chemical metal. The exhaust pipe section goes into the flex pipe, and sealed there too. It's a temporary fix, but will last a few months. I'm looking to offload it in the Autumn and switch to a petrol daily driver.

 

Used jubilee clips, but have ordered A2 stainless clips for rubber hoses and heavy duty exhaust clamps for central section.

 

Edited 28 April, 20197 yr by spartacus68

Just jumping in as had a call from the garage and my flexi pipe coming down from the DPF is blowing, he doesn't think he's going to be able to replace the down-pipe without replacing the DPF as well which was my worst nightmare.

 

Any ideas if this is the case, is there any way (he's pretty good with welding) he might be able to do some kind of repair or is it as he's thinking a definite all-in change?

 

 

9 hours ago, hollyp0p said:

Just jumping in as had a call from the garage and my flexi pipe coming down from the DPF is blowing, he doesn't think he's going to be able to replace the down-pipe without replacing the DPF as well which was my worst nightmare.

 

Any ideas if this is the case, is there any way (he's pretty good with welding) he might be able to do some kind of repair or is it as he's thinking a definite all-in change?

 

 

Anything is possible. The thing is, your mechanic will need to strip out the DFP and if it's still connected to the catalytic converter, that too. He's probably thinking it's easier to replace than repair, as the repair will always be temporary.

 

Depends on the flexi-pipe and if its blowing at the same location as mine? If it is, I'd strip out the catalytic converter, and add 2" diameter pipe as I have, extending say 8" or so, then reinsert back into the flexi, and seal that way. Should buy you a bit of time if nothing else.

On 30/04/2019 at 22:33, spartacus68 said:

Anything is possible. The thing is, your mechanic will need to strip out the DFP and if it's still connected to the catalytic converter, that too. He's probably thinking it's easier to replace than repair, as the repair will always be temporary.

 

Depends on the flexi-pipe and if its blowing at the same location as mine? If it is, I'd strip out the catalytic converter, and add 2" diameter pipe as I have, extending say 8" or so, then reinsert back into the flexi, and seal that way. Should buy you a bit of time if nothing else.

 

Ok thank you and for commenting on the other post, I'll note all of the above to him as well as the other link and go from there.

 

I think had I owned mine longer than 6 months I'd be more open to replace, but especially as the DPF guys have made me feel better that the filter sounds like it's doing what it should and they don't anticipate any DPF issues, just fix flexi and drive, drive, drive!

Literally just back from having the repair carried out at a local garage.

 

DPF, downpipe, flexi-pipe and broken section, just before the second CAT removed. 

 

New flexi-pipe welded in and, apparently, plates welded on to repair the crack in the pipe near the second CAT.

 

Now running nice and quiet again.

 

Total  cost, £200.

 

Too dark to see outside, and it's been raining, but, if the weather dries out, I'll see if I can get the thing up on my ramps and get under the car and get some photos of the repair, over the weekend.

Wow that's good, did they keep your existing DPF in? Also did they avoid dropping your subframe to access? 

 

Answer to the first question is, yes, the existing DPF was retained, just obtained an aftermarket flexi-pipe and welded it into place. after cutting out the old one, so no need to remap a new DPF onto the ICU, using VAGCOM.

 

Although I left the car in the morning and returned to pick it up at the end of the day, reading the Haynes Manual, it would seem the only way to get the work done would have been to lower the subframe; the flexi-pipe risks bending too far if you don't, apparently.

 

Have to wait and see what the fuel economy is like now. I was getting 70mpg after it started blowing again, in Wednesday night (probably the flexi-tube giving up the ghost), which goes to prove that modern diesels are incredibly fuel efficient, but the emissions control features do really bite into this efficiency.

On 04/05/2019 at 11:24, GlenP said:

Answer to the first question is, yes, the existing DPF was retained, just obtained an aftermarket flexi-pipe and welded it into place. after cutting out the old one, so no need to remap a new DPF onto the ICU, using VAGCOM.

 

Although I left the car in the morning and returned to pick it up at the end of the day, reading the Haynes Manual, it would seem the only way to get the work done would have been to lower the subframe; the flexi-pipe risks bending too far if you don't, apparently.

 

Have to wait and see what the fuel economy is like now. I was getting 70mpg after it started blowing again, in Wednesday night (probably the flexi-tube giving up the ghost), which goes to prove that modern diesels are incredibly fuel efficient, but the emissions control features do really bite into this efficiency.

Thanks that's all he can see too. 

 

I am now dubious as it's been a couple of weeks and smell is back which mean DPF light will be on again in next day or two and need a burn up the dual carriage way. 

I had it on 45 mins each way dual carriageway trip on Friday and wondering if its normal not to have had the sense to regen during that trip rather than start acting up after a long trip? 

19 hours ago, hollyp0p said:

Thanks that's all he can see too. 

 

I am now dubious as it's been a couple of weeks and smell is back which mean DPF light will be on again in next day or two and need a burn up the dual carriage way. 

I had it on 45 mins each way dual carriageway trip on Friday and wondering if its normal not to have had the sense to regen during that trip rather than start acting up after a long trip? 

 

I drove 322 miles (162 each way) to birmingham NEC. Didn't drive the car all weekend, when I drove it to work Monday (yesterday) it decided to regen... was kinda annoyed it needed to after a 322 mile journey

 

19 hours ago, JGrindel said:

 

I drove 322 miles (162 each way) to birmingham NEC. Didn't drive the car all weekend, when I drove it to work Monday (yesterday) it decided to regen... was kinda annoyed it needed to after a 322 mile journey

 

mine does it differently all the time. Sometimes after 500 motorway miles, sometimes after 200 miles. Sometimes it does a regen immediately after I come off a motorway 

On 28/04/2019 at 22:59, spartacus68 said:

Update. Great day for working under a car! Stripped out the catalytic converter. Turns out it's sheared just where it joins the flexi exhaust pipe from the DPF. Used an angle grinder to cut the exhaust clamps at the join at the back of the catalytic converter to the middle exhaust pipe. Disconnect sensor 4 and two control hoses to differential pressure sender and disconnect at hangers.

 

Managed to insert a length of 50mm exhaust pipe into the catalytic converter, clamp it on with exhaust gum and seal with chemical metal. The exhaust pipe section goes into the flex pipe, and sealed there too. It's a temporary fix, but will last a few months. I'm looking to offload it in the Autumn and switch to a petrol daily driver.

 

Used jubilee clips, but have ordered A2 stainless clips for rubber hoses and heavy duty exhaust clamps for central section.

 

Can i ask you what engine code do you have ? 

 

On this picture , you two differential pressure pipe outlets plus temperature sensor , which would indicate this round box is DPF. 

I am saying that because i just attempt yesterday to remove DPF from my car and we got confused what is what , as local garage where they do DPF removal saying round box is actual DPF not a CAT. I have engine CAYC engine code. 

It was I assume CAYC engine code. However I've since sold the car. What you're looking at is the catalytic convertor. The diesel particular filter sits behind the engine on the bulkhead. The corroded section is connected to a flexi pipe which goes to the DPF.

 

Cut my losses and sold it for £1400. Practically gave it away.