DPF Regeneration – Diesel Particulate Filter Automotive Dilemma

Categories: DPF Removal

Unwanted misery to diesel Car/Truck owners


For those who own late-model diesel cars; may it be Mazda, Mercedes, Nissan, Mitsubishi, Iveco, Citroen, Holden, Hyundai, Vauxhall, Volkswagen or Renault, you are probably familiar with the automotive term “diesel particulate filter (DPF)”.  Regular use of your car and you have grasped the fact that your DPF-equipped diesel vehicle cannot perform on the same level as the equivalent vehicle without a DPF.  ie a Mazda 3 or Mazda 6 fitted with a DPF does not compare in fuel economy, performance or efficiency as our DPF-deleted Mazda and you would like to know why this is so. From an automotive standpoint, a diesel particulate filter is a device that is designed in such a way that it removes soot, also known as diesel particulate matter, from the exhaust gases of your vehicle’s diesel engine. Since 2009 when the Euro 5 Standard came in force, the exhaust emissions standards for new cars has made it a legal requirement to have a DPF fitted in the exhaust gas of diesel cars to pass the emissions test in bid to reduce diesel particulate (soot) emissions with this kind of technology. However, this technology might seem like the ultimate solution to pollution and global warming to some, many see it only as a bane to their joy in owning a late model diesel.

DPF Filter solved the problem?

The DPF system consists of a filter a monitoring and maintenance system that ensures that the filter is working at optimum conditions. The filter in the DPF, which is made out of a special porous material, works by collecting particulate matter which is forced fed into the DPF by the exhaust from the engine before finally leaving the tail pipe. DPF’s bear a close resemblance to the true Cat and work by forcing engine gases to flow through a complex and porous ceramic structure. The cell walls being porous, allow the gases to pass through while the particulate matter gets deposited on the filter walls. As the particulate matter collects within the filter, the exhaust pressure builds up. The pressure is monitored by the computer in the diesel-powered vehicle and when it determines that the filter is clogged it causes the injection of raw diesel fuel into the exhaust system, which ignites and burns in the filter (regens) to clear particulate matter out of the DPF cell walls.  The DPF regeneration cycle that occurs at speeds above 72.4 km/h, happens every 160-560 kilometers and lasts an average of 30 minutes.

Active regeneration and passive regeneration

For better fuel economy, improved towing capability and diesel performance, the particulate matter trapped in the filter must be emptied regularly. This is done in two ways: active regeneration and passive regeneration. Active regeneration takes place when the soot level builds up to around 45-50%.  That’s when the ECU makes small adjustments to raw diesel injection, called post burn injection, and increases the exhaust gas temperatures. Increased exhaust temperatures causes the soot within the DPF to burn away.
In passive regeneration, the DPF and particulate matter cleaning process takes place automatically when the exhaust temperature is high (circa 600 deg Cel).   Many diesel trucks and cars rarely reach this sort of temperatures which has forced the manufacturers of diesel engines to come up with the active DPF regeneration process.
Although a DPF filter usually removes almost 85% of the soot produced by diesel engines and consequently cuts soot emissions by 80%, these devices are not suitable for everyday city motoring.  For most pre-DPF truck or car owners who used to cruise at an average of 15 liters per 100 kilometers, it comes as a shock to realize that a brand new $50,000+ DPF-installed diesel vehicle achieves a much less desirable fuel economy. Interestingly, since more diesel fuel has to be used to heat the filter this translates into higher diesel emissions let alone the increased fuel consumption.
Although there are plenty of ways to keep your DPF system clean and behaving properly such as keeping the engine at high operating temperature, driving in 4th or 5th gear and above 80 km/h, keeping the engine speed at an average 2500rpm and using additives such as Ad Blu, many diesel vehicle owners are going for a DPF delete procedure from Chip Tuning which is essentially the removal of the factory ECU the coding that works the DPF and exhaust recirculation valve (EGR) and then removes the DPF itself from the exhaust.   It is important to note that process of DPF delete for Mazda, Fords, Chevy, Mercedes, Dodge Volkswagen, Mitsubishi and Nissan or any diesel vehicle requires a great deal of technical knowledge (as it involves the removal of the car’s tuning file and reorganising the ECU coding and structure, the team at Chip Tuning have perfected it.  Many clients are now happily enjoying their vehicle’s, DPF free and the added benefit of having a performance tune added to the vehicle at no extra charge. *
This unique process, perfected by Chip Tuning is by far the cheapest method of eliminating the problem and this is a one time … never see problem again fix!
This clever procedure sees the fuel economy and horsepower lifted to very acceptable levels and are guaranteed to put a smile on the face of the vehicle owner.
Some auto repair companies, due to lack of expertise, will just remove the filters in your DPF equipped vehicle hoping to solve the problem. What most do not know is the factory ECU is smart enough to know that a filter has been tampered with and will constantly bring up an Engine Check light and put the car into limp mode.  Sensors that still communicate the condition of the vehicle’s DPF and not having one fitted is the same as one being blocked.  The ECU knows all!    What’s more is the fact that having another filter installed again to get your car on the road again will cost you a many thousands of dollars while in essence you are still stuck with the initial problems of the DPF system albeit removed for a short period of time.  Thus, to do a DPF delete, it is essential to consult the services of qualified remapping specialists and tuners such as Chip Tuning.
* NB:  Some vehicles require the factory ECU to be removed and have some additional connections made inside the ECU for it then to allow it to be reflashed with the DPF portion removed
Learn more about DPF

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