Where to source a new DPF

[BillyCool]

Team Big Brains,

My car is in the garage for a new DPF.

2014 FR ST 2.0 TDI 184 CUPA engine code. 155,000 miles.

Car was doing a regen every 30 miles and garage said it was knackered.

The price for a genuine VAG one was £3200+VAT. Ouchie, I asked about an OEM one. They said that they prefer not to fit them as they tend not to last and can be a pig to fit. The price for an OEM one was £1200+VAT. That was effectively the best of the rest (you can get cheaper ones but they said they wouldn't touch them). They almost reluctantly agreed to fit the OEM one.

They tried to fit the OEM one and it would not seal with the turbo as the mountings were slightly off (even after trying to tweak it) and they said it would not be right.

Back to plan A. Get a VAG one for a second kidney. That was on backorder from Germany and was a 10 day wait. That was 15 days ago. Got a call today to say it's delayed until 23rd March. Not good.

So - does anyone know where I might be able to get a VAG one without waiting another 2 weeks or if they know of an OEM DPF that is any good. I'm not blaming the garage. I'm just super grumpy about the delay and price of the VAG one. I'm invested in the car so prepared to spend money on it but it's just dragging on and I'd rather not spend £5k on it if I can help it. I'm also getting new injectors so it's going to cost more.

I'd appreciate any thoughts/input/winning lottery tickets.

 

[James_R]

TPS or the dealership parts department both have the ability to check if any dealership or TPS branch in the country has one on their stock list.

It'll be the same price, you might have to travel to get it, but it'll solve your issue.

 

[BillyCool]

TPS or the dealership parts department both have the ability to check if any dealership or TPS branch in the country has one on their stock list.

It'll be the same price, you might have to travel to get it, but it'll solve your issue.

Thanks @James_R . I think they've gone via TPS and been told that there are literally none in the country and they are waiting for them to come from Germany on back-order.

I'll happily be corrected if anyone can tell me any different.

 

[SuperV8]

The DPF has a weird mounting system - 4x compensation elements.
Were these adjusted correctly?
You are supposed to connect the flange clamp to the Turbo first - then fit the mounting bolts by hand, in quite a complicated tightening sequence.

 

[BillyCool]

The DPF has a weird mounting system - 4x compensation elements.
Were these adjusted correctly?
You are supposed to connect the flange clamp to the Turbo first - then fit the mounting bolts by hand, in quite a complicated tightening sequence.

View attachment 53128

View attachment 53129

Thanks for that. I'm pretty sure that is what they are doing. The DPF is literally catching on the bodywork and they say they'd have to put a big dent in the DPF to fit. I guess we'll see how the really expensive genuine one gets on when it arrives.

I'll really appreciate it when I get it back. The 1.2 Dacia Sondero courtesy car is not that inspiring to drive. MPG is very good though. Other than that, dead slow.

 

[SuperV8]

What was the part number of the DPF you bought - which didn't fit?

 

[BillyCool]

What was the part number of the DPF you bought - which didn't fit?

I don't know which part number they used but the OEM was a Walker one. Possibly WALKER 73298. I can't say for sure.

They said it was basically too big and the brackets didn't have enough adjustment and it was pressing against the bulkhead (I think). This meant that the turbo gasket didn't seal properly and was causing a leak. They weren't very impressed with it.

I'm afraid that's all the info I have.

 

[Mr Pig]

I thought the DPF could be cleaned out?

 

[Mo_86]

Just gut it and get a good map, your turbo will thank you too.
While your at it blank the egr.

 

[BillyCool]

I thought the DPF could be cleaned out?

Yes and no. I had it "cleaned" on the car and it had very little effect. When the garage tested it they said it was knackered. Some DPF's can physically break down inside and cleaning won't help. You can also get them cleaned when removed but again the results are variable.

I'm not an expert on it but can only go by what the garage tell me. They said a clean might buy me 6-12 months and based on the 7-8 hours labour cost to swap a DPF it's not realy worth the risk.

I can't say I'm happy about it but I'm planning to keep the car so I'll have to bite the bullet. The new DPF is coming from Germany and it delayed until next week. I'm also starting to develop a soft spot for the Dacia Sondero, which is also troubling me.

 

[SRGTD]

I'm also starting to develop a soft spot for the Dacia Sondero, which is also troubling me.

I had the Stepway version of the Sondero as a courtesy car last year while my Renault Clio was at the dealers for a software update. I’d describe it as a ‘no frills’ car without some of the creature comforts that car manufacturers have brainwashed us into thinking we can’t do without. IMHO ‘no frills’ is no bad thing; less to go wrong.

 

[R3k1355]

Find a decent used DPF, confirm the inside isn't damaged or breaking down. Send it for a clean on a proper DPF cleaning rig (not just a spray of aerosol down it's throat)

I'd say that'd do you well for a number of years, providing there isn't something faulty on the car that's filling the DPF up faster than usual.

 

[Mr Pig]

Yes and no. I had it "cleaned" on the car and it had very little effect. When the garage tested it they said it was knackered. Some DPF's can physically break down inside and cleaning won't help. You can also get them cleaned when removed but again the results are variable.

I'm not an expert on it but can only go by what the garage tell me. They said a clean might buy me 6-12 months and based on the 7-8 hours labour cost to swap a DPF it's not realy worth the risk.

I can't say I'm happy about it but I'm planning to keep the car so I'll have to bite the bullet. The new DPF is coming from Germany and it delayed until next week. I'm also starting to develop a soft spot for the Dacia Sondero, which is also troubling me.

My understanding is that you can only clean the DPF properly by taking it off the car. I've never heard of the DPF breaking down.

 

[SuperV8]

My understanding is that you can only clean the DPF properly by taking it off the car. I've never heard of the DPF breaking down.

They can crack or melt internally. Obviously if this has happened - cleaning won't help!

 

[BillyCool]

I had the Stepway version of the Sondero as a courtesy car last year while my Renault Clio was at the dealers for a software update. I’d describe it as a ‘no frills’ car without some of the creature comforts that car manufacturers have brainwashed us into thinking we can’t do without. IMHO ‘no frills’ is no bad thing; less to go wrong.

Can't argue with that. I can see why people have a cost-effective commuting car. For me to do 7 miles each way to work with very little chance of having any fun, it makes sense. Fuel economy is excellent as well. The car just has no soul and overtaking is a thing of the past! I'll be very happy to get my car back.

 

[BillyCool]

Find a decent used DPF, confirm the inside isn't damaged or breaking down. Send it for a clean on a proper DPF cleaning rig (not just a spray of aerosol down it's throat)

I'd say that'd do you well for a number of years, providing there isn't something faulty on the car that's filling the DPF up faster than usual.

I was thinking that could be an option. I think it's hard to know if a 2nd hand cleaned one will last. It's a bit of a lottery. The 184 engines (CUPA/CUNA) are known for burning oil and as such might fill the DPF up quicker. I don't really need a brand new one but I don't the same issue 2-3 years down the line.

 

[BillyCool]

My understanding is that you can only clean the DPF properly by taking it off the car. I've never heard of the DPF breaking down.

It can happen under certain conditions:

Internal breakdown of a Diesel Particulate Filter (DPF) occurs when the ceramic honeycomb structure inside the filter cracks, melts, or becomes permanently blocked with ash, rendering it unable to regenerate and remove trapped soot. This failure is often a catastrophic result of long-term ignoring of warning lights, failed regeneration, or underlying engine issues that allow excessive soot, ash, or oil into the exhaust system.

Causes of DPF Internal Failure

• Soot Overload (Severe Blockage): When the DPF reaches 85% or more soot capacity, it cannot safely regenerate, and the excessive heat from attempted regeneration can melt the ceramic core.
• Excessive Ash Accumulation: Unlike soot, ash is a byproduct of oil consumption and fuel additives that cannot be burned away. It eventually clogs the filter pores permanently.
• Turbocharger Failure: A broken turbo can push engine oil directly into the exhaust, which then coats the DPF ceramic and breaks it down.
• Improper Engine Oil: Using non-low-SAPS (Sulphated Ash, Phosphorus, and Sulphur) oil produces excessive ash, plugging the filter.
• Faulty Sensors: Defective differential pressure sensors may fail to trigger regeneration, causing the soot to accumulate until the filter is unusable.
  

Symptoms of Internal DPF Breakdown

• Irreversible Power Loss: Constant "limp mode" where the engine restricts speed and power.
• Visible Soot/Smoke: Black or blue-grey smoke from the exhaust indicates that the filter is no longer trapping particulates.
• Physical Damage: The ceramic core may fracture, causing rattling noises inside the exhaust.
• Frequent Regeneration Attempts: The car repeatedly tries to initiate regeneration, causing high idle speeds and fuel consumption.
• Increased Oil Consumption: A failed filter can cause higher backpressure, leading to engine oil leaks or consumption.

Consequences and Fixes
When a DPF has suffered internal breakdown, it generally cannot be repaired or cleaned; it must be replaced.

• Engine Damage: Ignoring a broken DPF can lead to severe backpressure, which can cause turbocharger failure and damage to the engine itself.
• Replacement Cost: A new DPF, along with diagnosis and labor, often costs over £1,000–£3,000 (roughly $1,500–$4,000+).
• MOT Failure: In the UK and similar jurisdictions, a failed or removed DPF will cause an automatic MOT failure.

I have to trust what I'm being told as I do not want to repeat the exercise!

 

[SuperV8]

I was thinking that could be an option. I think it's hard to know if a 2nd hand cleaned one will last. It's a bit of a lottery. The 184 engines (CUPA/CUNA) are known for burning oil and as such might fill the DPF up quicker. I don't really need a brand new one but I don't the same issue 2-3 years down the line.

I have been looking at this option - but second hand ones still priced quite high on ebay, so wouldn't be much different than getting a new aftermarket one

 

[R3k1355]

I was thinking that could be an option. I think it's hard to know if a 2nd hand cleaned one will last. It's a bit of a lottery. The 184 engines (CUPA/CUNA) are known for burning oil and as such might fill the DPF up quicker. I don't really need a brand new one but I don't the same issue 2-3 years down the line.

Maybe sling a used one in, run the car for the next 12 months and then stick it up for sale before any problems come to light?