Recommendations for new DPF, injectors and EGR cooler.

[BillyCool]

Hi Team,

My car had reached that point where it needs some TLC.

2.0 tdi FR ST 184 bhp CUPA engine code. 156,000 miles.

New DPF - it's knackered. Car regens every 30 miles and garage says it's toast.
New EGR cooler and valve (my choice to replace whilst DPF being done as they are prone to fail).
New injectors - #1 is over fuelling a lot and #3 isn't much better. Get lots of engine wobble at idle.

I'm invested in the car and plan to keep it, run it into the ground and bury it. I was expecting maybe a £5k bill for everything. However.

Quoted today:

DPF - genuine £3,345+VAT plus 6 hours labour
Cooler - £400+VAT and some labour but not much as the cooler is taken off anyway to get to the DPF.
Injectors - £1480+VAT plus fitting

Total is about £8k. Much more than I expected.

DPF price is massive. Garage said it's a dealer part and fully warrantied. They have just sourced an OEM one that they are happy to fit and that is £1100+VAT, more in line with my expectations.

I'm going to delay the injectors until DPF is done.

Are there any good OEM brands for DPF's? Autodoc has a few but I have no idea what's good. I just want to understand the price differences.

Also injectors. Any ideas whether it's worth trying to save a few £ or go with the fully branded/warrantied ones.

Thanks.

 

[SuperV8]

Ouch - my 150,000+ mile CUPA is regening around 70 miles so i'm also looking at DPF options!
Luckily our DPF is able to be split (later versions are welded!) - 04L131606EX it's actually a combined DPF & CAT - which is one of the reasons the OEM part is so expensive. There are aftermarket companies selling just the DPF part - and large band clamp.

For example:

https://www.autodoc.parts/nap-cleanair/21616647

Which is using the more expensive silicon carbide.

I have also been musing if I can clean my existing DPF - it's just such a pain to get to:

Regarding egr cooler.
04L131512D

was replaced circa 2016 by
04L131512BQ

Which went from rectangle holes - to round. These egr coolers are subject to large thermal stresses - and would think the round version copes with this better? Personally I would only change this if it was leaking.

Regarding your injectors - have you tried diesel fuel system cleaners/additives?
OEM number 04L 130 277 AE = Bosch 0 445 110 470
Also I would inspect your dogbone mount.

My next job is changing my cylinder head cover as it has a slight mist around the back edge - and I think it is letting too much oil through as I can see oil traces into the turbo. - which might be contributing to my oil consumption?
And I'll also be changing my air to water intercooler as have noticed a leak (another common problem!)

 

[R3k1355]

Should be able to remove the DPF and have it properly cleaned on a machine, regain 90% of original capacity.

They all need it eventually, on-car cleaning is ok but only works to a point.

 

[R3k1355]

This is how a properly knackered DPF looks on a cleaning machine.

5.146 Aufrufe · 26 Reaktionen | Went out to Phils 2012 Vivaro which had over 300 mbar at idle on his dpf due to a broken boost pipe . Van had also been due a service to did that as well . Back on the road and back to work within 24 hours . | Dpf Cl

Went out to Phils 2012 Vivaro which had over 300 mbar at idle on his dpf due to a broken boost pipe . Van had also been due a service to did that as well . Back on the road and back to work within...

www.facebook.com

 

[cuthound]

Get it Terracleaned

Got my DPF cleaned out - Page 1 - General Gassing - PistonHeads UK

 

[BillyCool]

Thanks for the replies.

@SuperV8 They did say the CAT wouldn't need replacing so I'm not sure if they'll do just the DPF. They said a lot of aftermarket stuff was rubbish.

My DPF was chemically cleaned on the car before Xmas and it's not done much. Can't comment on how good a removal and a clean would be. For peace of mind I'd rather have a new one.

I'm changing the EGR cooler BEFORE it starts to leak . It's a known issue and since they remove it to get to the DPF most of the labour is already paid for. Might as well get it done, as well as the EGR valve. I actually want to inspect the old ones and see how gunked up there are.

The injectors are on hold until the DPF is done and I can sell another kidney to pay for it. The car runs on BP Ultimate and since 2 of them are over fuelling and not blocked I'm not sure if a cleaner would help. I can stick some through and see what happens. It also had a carbon clean 4 weeks ago and that highlighted the injector issues.

It's in for the DPF/EGR tomorrow. See what it's like after that. I suspect the injectors will still need doing.

The joys of car ownership.

 

[BillyCool]

Should be able to remove the DPF and have it properly cleaned on a machine, regain 90% of original capacity.

They all need it eventually, on-car cleaning is ok but only works to a point.

Garage suggested it's knackered. For the time and labour to remove and refit I may as well fit a new one. Can't be doing with the aggro!

 

[SuperV8]

Thanks for the replies.

@SuperV8 They did say the CAT wouldn't need replacing so I'm not sure if they'll do just the DPF. They said a lot of aftermarket stuff was rubbish.

My DPF was chemically cleaned on the car before Xmas and it's not done much. Can't comment on how good a removal and a clean would be. For peace of mind I'd rather have a new one.

I'm changing the EGR cooler BEFORE it starts to leak . It's a known issue and since they remove it to get to the DPF most of the labour is already paid for. Might as well get it done, as well as the EGR valve. I actually want to inspect the old ones and see how gunked up there are.

The injectors are on hold until the DPF is done and I can sell another kidney to pay for it. The car runs on BP Ultimate and since 2 of them are over fuelling and not blocked I'm not sure if a cleaner would help. I can stick some through and see what happens. It also had a carbon clean 4 weeks ago and that highlighted the injector issues.

It's in for the DPF/EGR tomorrow. See what it's like after that. I suspect the injectors will still need doing.

The joys of car ownership.

Sounds a good plan, I have been looking into changing the EGR at a later date 'just in case' - and is still a ball ache of a job - so wise to do it at the same time.
Would be interesting to see photos of yours.

Yes, I can't see those on vehicle 'DPF clean's' doing much for a long term fix - maybe help to turn the DPF light off short term for an MOT!

Has your DPF light ever come on? mine has never come on.

Speaking to an expert diesel guy I work with about injectors - and he said injectors can be cleaned and greatly improved - however there is a risk of the cleaning also loosening varnish which could also be masking a worse issue so you could make them worse! As you say - the joys of car ownership!!

Guess you're also due your second cambelt soon?

 

[BillyCool]

Sounds a good plan, I have been looking into changing the EGR at a later date 'just in case' - and is still a ball ache of a job - so wise to do it at the same time.
Would be interesting to see photos of yours.

Yes, I can't see those on vehicle 'DPF clean's' doing much for a long term fix - maybe help to turn the DPF light off short term for an MOT!

Has your DPF light ever come on? mine has never come on.

Speaking to an expert diesel guy I work with about injectors - and he said injectors can be cleaned and greatly improved - however there is a risk of the cleaning also loosening varnish which could also be masking a worse issue so you could make them worse! As you say - the joys of car ownership!!

Guess you're also due your second cambelt soon?

Garage said a lot of the EGR coolers will have a new EGR valve attached anyway, so it's changed by default.

I do hope to get some photos. I intend to take the EGR cooler and valve away with me if I can.

Never had a DPF light come on. Car still completes a full regen, even if it does it every 30 miles!

Can't be arsed to faff with the injectors. Probably just bite the bullet and get them done.

2nd cambelt was done Oct 2024. The 1st change was done early due to the stupid electronic "switchable" water pump failing. Was replaced with a non-switchable version and never had an issue. More VAG witchcraft.

 

[R3k1355]

If it's still able to fully regenerate it's not ******, it's just full of ash. To be honest you could go for an on-vehicle clean and get some good improvements.
I've heard the Terraclean DPF one is best, find a local garage that uses their solution.

Instead of 8 grand you'll be in just a couple hundred quid

 

[BillyCool]

If it's still able to fully regenerate it's not ******, it's just full of ash. To be honest you could go for an on-vehicle clean and get some good improvements.
I've heard the Terraclean DPF one is best, find a local garage that uses their solution.

Instead of 8 grand you'll be in just a couple hundred quid

Thanks - but I've had an on car clean and it didn't work. The garage says it's knackered so I'm replacing it. I can't be @rsed to mess around with it any more.

 

[SuperV8]

Garage said a lot of the EGR coolers will have a new EGR valve attached anyway, so it's changed by default.

I do hope to get some photos. I intend to take the EGR cooler and valve away with me if I can.

Never had a DPF light come on. Car still completes a full regen, even if it does it every 30 miles!

Can't be arsed to faff with the injectors. Probably just bite the bullet and get them done.

2nd cambelt was done Oct 2024. The 1st change was done early due to the stupid electronic "switchable" water pump failing. Was replaced with a non-switchable version and never had an issue. More VAG witchcraft.

Did you ever get any photos of your old EGR valve?

How's your new DPF performing now you have had a few months under its belt?

In my ongoing DPF quest I changed my cylinder head cover as it was misting around the edges, and also had some oil in the outlet pipe into the intake (I did change the diaphragm last year) and notice since changing this cover my regens have gone up from about 30-40miles to 60-70 miles! Also seems to drive a little smoother, and the vacuum pump is quieter!

I was all set in prepping for a new DPF - but then did a forced regen - and my idle DPF pressure differential went from 20+ish to 9 - which for me suggest my DPF issue isn't due to ASH - but rapid SOOT build up?

 

[BillyCool]

Did you ever get any photos of your old EGR valve?

How's your new DPF performing now you have had a few months under its belt?

In my ongoing DPF quest I changed my cylinder head cover as it was misting around the edges, and also had some oil in the outlet pipe into the intake (I did change the diaphragm last year) and notice since changing this cover my regens have gone up from about 30-40miles to 60-70 miles! Also seems to drive a little smoother, and the vacuum pump is quieter!

I was all set in prepping for a new DPF - but then did a forced regen - and my idle DPF pressure differential went from 20+ish to 9 - which for me suggest my DPF issue isn't due to ASH - but rapid SOOT build up?

I do have the EGR cooler and attached EGR valve somewhere. I'll dig it out and take some photos.

I did not get a brand new DPF in the end due to price (£3300+VAT) and the fact it had to come from Germany and was delayed by 3+ months. The garage sourced a lower mileage (80k?) DPF that got bench cleaned and fitted. My one was melted and beyond help but a lower mileage one could still be bench cleaned fairly successfully. Worked out much cheaper. So far, the car runs a lot better as I think it can actually breath better (I really mean the DPF is less restricted). MPG has gone back up to 45-48mpg from a 35-38mpg range.

If you're DPF pressures have reduced to single digits that's really good. Might be short term but keep an eye on it. The CUPA/CUNA's are prone to use a lot of oil so the DPF may be oiling (sooting) up quicker or oil is being introduced elsewhere. Low SAPS oil is recommended and I change oil & filter every 6,000 miles.

A lot of people will DPF delete but that's up to you. One thing that I was told about the VAG DPF's is they can be fully dismantled, so you can strip it down, remove certain parts and put it back together again. No external visual clues. Can impact emissions test but some people say it still get's through.

My next car will be petrol as I do less miles now and diesel/DPF issues just suck. Just replaced the injectors as well and that wasn't cheap.

 

[SuperV8]

I do have the EGR cooler and attached EGR valve somewhere. I'll dig it out and take some photos.

I did not get a brand new DPF in the end due to price (£3300+VAT) and the fact it had to come from Germany and was delayed by 3+ months. The garage sourced a lower mileage (80k?) DPF that got bench cleaned and fitted. My one was melted and beyond help but a lower mileage one could still be bench cleaned fairly successfully. Worked out much cheaper. So far, the car runs a lot better as I think it can actually breath better (I really mean the DPF is less restricted). MPG has gone back up to 45-48mpg from a 35-38mpg range.

If you're DPF pressures have reduced to single digits that's really good. Might be short term but keep an eye on it. The CUPA/CUNA's are prone to use a lot of oil so the DPF may be oiling (sooting) up quicker or oil is being introduced elsewhere. Low SAPS oil is recommended and I change oil & filter every 6,000 miles.

A lot of people will DPF delete but that's up to you. One thing that I was told about the VAG DPF's is they can be fully dismantled, so you can strip it down, remove certain parts and put it back together again. No external visual clues. Can impact emissions test but some people say it still get's through.

My next car will be petrol as I do less miles now and diesel/DPF issues just suck. Just replaced the injectors as well and that wasn't cheap.

Glad yours has improved.
Wow your DPF was melted! - did you have any soot in your tail pipe?
Would be interesting to see photos of your old injectors as well?
These are mine - when I changed my cylinder head cover a couple weeks ago:
Right one a bit rusty - and the tip on the left one a bit black and sludgy! I had to disturb the right one when I changed my diaphragm last year - might explain its rust.
I'm planning on getting their spray's tested, though my idle injector deviation is fine.

These are my cams - look perfect at 160,000 miles!

I'm closely monitoring my oil consumption, it does use a 'little' but much less than VW's official 'allowance' i'm keen to see if this new cylinder head cover reduces my oil consumption.

 

[BillyCool]

No soot really to speak off. I think they said that part of the centre core of the DPF is ceramic or something. Not sure but it gets so blocked up you can't clean it, even on a bench. I never saw my injectors so can't comment. If far left is you #1, it does look a bit mucky although your deviation rates appear ok. I was losing some oil via rocker cover and oil cooler and replacing both seemed to help stop some of the oil usage. I literally topped my oil up this week. Maybe 400ml per 1000 miles, which by VAG standards seems okay. Your cams do look good. It's the piston rings I'd like to see.