DPF (Diesel Particulate Filter) removal is remedy for the current wide-spread emissions system failure on later model diesel vehicles. This very common failure occurs when the DPF gets old or fails to regenerate as per the normal factory regen process. Once the DPF becomes blocked, the car will usually go into Limp Home Mode until the problem is fixed. This has been known to leave people stranded in the bush, in remote country towns or when 4 wheel driving. A forced regeneration of the DPF will usually only last for a short period and will require a new $3000.00 DPF from the manufacturer.
A DPF Removal Service we are offering worldwide means that we can correct this problem from ever happening again. We can also combine a DPF (Diesel Particulate Filter) removal (known as DPF OFF) together with EGR OFF (Exhaust Gas Recirculation removal) and a Performance remap of your factory ECU. In short, we can help correct problems with DPF and poor performance at the same time. For more information please call us on 02 80901881 .
The process involves reading the current factory engine management file / program (your vehicle’s Factory ECU) and with this file we then customise it for whatever the customer desires or whatever fixes need to be applied: Whether it be a Performance Tune, turning off the DPF and EGR or the Speed Limiter etc (ie DPF OFF, EGR OFF and SPEED LIMITER OFF). Then, we flash the new customised file into the factory ECU and test drive the vehicle to confirm the tune is OK. Then we are done. You then have the opportunity to experience the amazing results from the first time you test drive the vehicle.
NSW vehicle owners need to be aware that it is an offence to use a vehicle on any road or roads related area in NSW if any anti pollution device has been removed unless the vehicle is being used in motor racing or off road motor sports. Other Countries, States and Territories may have similar restrictions.
What is a Diesel Particulate Filter (DPF)
A DPF is a device designed and integrated into the Diesel Engine exhaust system to trap and remove Diesel Particulate Matter from the exhaust gasses of the diesel engine. Much like the Catalytic Converter on conventional petrol engines, the DPF works to remove harmful toxins and lower the emissions of your diesel engine making it more environmentally friendly.
The aim of the DPF is to remove 80% of the diesel particulate matter (emissions) and although a great concept, it brings about a whole new line of problems. We are taking calls constantly from anxious customers and mechanics across the country when their DPF light is illuminated on the dash, indicating that there is at least a partial blockage in the DPF system.
DPF Problems You May Not Know
The DPF works to trap and remove diesel particulate matter from the exhaust gasses of the diesel engine before it exits the exhaust. This is removed into the atmosphere, simply removed from the gasses that flow through the exhaust to help lower emissions. Imagine, a DPF is like a honeycomb on the inside, similar to the Catalytic Converter (CAT) of a petrol engine. As the gasses flow through it, the DPF will trap the harmful diesel particulate matter and with it’s advanced technology break it down to remove as much of it as possible normally (between 80%-100%). The diesel particulate matter is burnt off at very high temperatures in the DPF and left behind is a very fine soot residue. The problem is this soot, it has no-where to go and so will then begin a blockage in the DPF system and this is how common DPF Problems occur.
The soot and matter will partially block your DPF causing the DPF light to illuminate on the dash (normally when 45% blockage is reached) at which point regeneration is required to get the DPF back in to it’s safety zone. Regeneration is the DPF’s way to clear the blockage through continuously burning it at higher temperatures and allowing the now harmless produce to escape through the exhaust system. There are two types of Regeneration processes which will be explained further below.
Sometimes the DPF light will appear on the dash intermittently, this does mean there is a partial blockage in your DPF and a regeneration process is required. You should make yourself aware of this process but many people are unsure or have no idea of this DPF system as it’s still very new and not explained to everyone. If you bought your vehicle from new at a dealership, then this would have most likely been explained at the point of sale but in the second hand car trade, you can’t expect this type of information to always be passed on.
What happens is drivers see the light, then see it go off and ignore it – not knowing it’s a partially blocked DPF. They continue to drive and again it will illuminate the DPF light on the dash and go off again but eventually it will stay on permanent and in most severe cases bring on the Engine management light and even the Coil Light which could start blinking. If this happens, you will lose all power and the vehicle will fall into “Limp home Mode”. This is the automatic reaction of the Engine Management ECU and if you’re at this stage then unfortunately it will be a costly repair. You could be looking at having to replace the DPF unit and having your Engine Management ECU reprogrammed.
A DPF replacement will cost you between $4,000 – $10,000 ( + Labour ) from the manufacturers, depending on the Make and Model of your vehicle and location. Dealers in Wollongong NSW have been found to add an extra $3,000 per job!!!
Resetting the ECU light will cost you a further $150 – $250 and then you will have to be on the lookout for the next time the DPF light comes on to take the appropriate action to ensure the damage is not done all over again as if you fail to act, then you could potentially void any warranty given with the new DPF unit costing you double.
Passive regeneration is an automatic regeneration which often occurs on drives where there is prolonged high exhaust temperatures like for example on motorway type runs, but it can’t be said that all cars get the required long journey motorway type trips necessary to complete a passive regeneration of the DPF system and so manufacturers have had to adapt the technology and designing an “active” regeneration process controlled by the Engine Management Computer also known as the Engine Control Module (ECM).
When the diesel particulate (matter) loading in the DPF reaches a pre-set limit (normally around 50%), the ECU will make minor adjustments to the fuel injection timing system which will in turn increase the exhaust temperatures and help initiate the DPF regeneration process. This is a smart way of getting a motorway type temperature to build up inside the DPF system and begin a full regeneration to bring the unit back to good health, however, if the journey is a bit stop/start where you’re in a built up city with traffic then the chances are the regeneration will not complete and eventually the DPF light will illuminate on the dash to tell you that the DPF system is partially blocked.
At this point it is recommended that you try to find time to complete a full regeneration and this can be done on a simple 10 minute or so drive of speeds above 80kph.
If you do not do this and choose to ignore the light, it may go out but come back on and as you continue in a relatively slow, stop/start pattern of driving the diesel particulate matter loading will continue to build up and clog up the DPF system until it reaches closer to 75% blocked at which point you can expect other more serious warning lights to appear on the dashboard. By now, driving at speed alone will no longer be sufficient and the car will need to go to a garage or dealership for regeneration. The other lights may be the engine management light constantly on and possibly even the glow plug light blinking constantly. It is not advised to continue driving the vehicle under these conditions to avoid further costly damages to the DPF system and other mechanical components e.g Turbo and Engine.
Common vehicles suffering the DPF system failure
The DPF system is fitted to a wide range of cars and in fact is being installed on almost all new Diesel engines so the problem will in future become more and more common, however, at this moment in time we’ve put together a small list of the most common cars which we’re having to deal with on a weekly basis suffering from the DPF problems:
- Alfa Romeo
- Mitsubishi Pajero
- Nissan Navara
We can do DPF removal on all the above vehicles and many more….
DPF additives and how they work?
The most common type of DPF systems feature an in-built oxidising catalytic converter, which is located close to the engine where you will find the exhaust gases will still be relatively hot so that passive regeneration is possible. In some vehicles there’s not always space nearer the engine in which case some manufacturers use a different type of DPF system, one which relies on a fuel additive to lower the ignition temperatures of the diesel particulate matter particles so that the DPF can be located further away from the engine.
The DPF additive is usually stored in a separate tank and is automatically mixed in with the fuel when you go to fill up. Only very small amounts of theDPF additive are required for regeneration for example on average 1 litre of DPF additive would cover around 2800 litres of fuel, enough to cover circa 45,000 kms at 7.1 litres per 100. With this type of DPF, regeneration would be initiated by the ECU roughly every 300 or so miles depending on the vehicle and will normally take 5-10 minutes to complete. Normally you won’t even notice this process taking place and if anything, once regeneration is completed you might see a glimpse of white smoke exit the exhaust and that’s it.
How much are you expected to pay on average for repairs?
Ignoring the warning lights and allowing the diesel particulate (matter) loading to continue to build up will lead to complete failure of the DPF in which case it would require a replacement unit which can cost anything from $4,000 – $10,000 as mentioned above. After replacing the DPF you will need to reset the ECU which is an additional charge, normally between $150 – $250.
Most of our customers prefer to have the DPF removed entirely. We can reprogram the vehicles Engine Control Module (ECM) also known as the Engine Control Unit (ECU) so that you no longer have warning lights being lit up on your dash and at the same time save on fuel costs and gain extra power out of the engine as the DPF system restricts the natural flow of exhaust gasses. Reprogramming the ECU will also eliminate the possibility of the engine running into LIMP Mode caused by the DPF system. We charge $1999.00 for the full drive in drive-out service which includes engine oil and filter service.
Will this cause my Vehicle to fail an Emissions Test?
Not with us! Though it is illegal to remove any emission device if the system leaves the car incapacitated then removal is the only option. Thus, it is not illegal to remove the DPF if the system is causing the vehicle to leave you stranded and unsafe as is the case when the DPF fails. This can be confirmed by any government motor vehicle facility.
What we do is also unique, when we re-map the ECU we download the ECU data and manually search through the 1000’s of data strings to locate and remove all DPF data strings. This is the ONLY sure way to delete a DPF system completely without problems occurring.
Legislation. What the “Environment Protection (vehicle emissions) Regulations” say is….
A person must not, without just cause, alter, replace or modify the engine or the exhaust system or fuel system of any motor vehicle in a way that – (a) departs from the manufacturer’s design: or (b) increases the rate of discharge of any of the constituent parts of emissions or (where applicable) defeats the intended upward discharge or dispersion of the emissions.
Your argument is that you have “just cause“. The vehicle is not fit for its intended purpose with the DPF installed. Having to go for an otherwise completely unnecessary drive every couple of hundred kms to regenerate the filter, or worse having to take the car to a dealer to have a forced regen is totally unreasonable AND CREATES THE VERY EMISSIONS PEOPLE ARE TRYING TO AVOID. Worse still is going into limp mode in a remote location or driving with the caravan or boat up a big hill with a truck barrelling up the road could very well put you and your family in a life threatening situation.
Also, truth be known, there is no road-side testing in Australia for diesel particulate at time of writing.
The regulations say nothing about a car with a diesel engine needing a catalytic converter or a DPF. Simply, a VISUAL diesel smoke test is performed by a licensed mechanic.
For more information on this and how we can help, please contact us at email@example.com or call 02 8090 1881