Particulate Filter Failure: Causes & Solutions

Hello everyone.

I drive an Audi A7 3.0 TDI (245 hp). It currently has approximately 172,000 km on the odometer and has had an *** chip tuning installed since the beginning (approximately 300 hp).
MKB: CDUC

The car is driven quite rarely, and when it is, it's usually only for long distances (more than 500 km). However, when it is driven, it's driven frequently over those long distances. Short trips are virtually never done.

"Recently, after starting the engine, an error message appears saying "Particulate Filter System Malfunction." It's also noticeable that the engine is running in a limited mode (it doesn't rev above 1500-2000 RPM and lacks power)."
After restarting the engine, everything returns to normal without any loss of power or other issues - only the yellow preheating lamp flashes. The message then disappears. Sometimes, the lamp is also off again (after a several-hour driving break).

Here's the error memory from the engine control unit. I've read quite a bit about it, and I'm now going to replace the differential pressure sensor, mostly because it seems to fail frequently, and secondly because it's the only sensor error that has been detected multiple times.

I also tried to capture some measurements, but honestly, I can't really make much sense of them. Maybe you can see something in the data, or tell me what I should be measuring.

Based on the driving profile, the mileage, and the oil ash volume reading of 0.21, I don't believe the DPF is full.

Code:

Montag,06,August,2018,19:01:56:13611 VCDS Version: DRV 18.2.1 läuft auf Windows 10 x64 http://shop.dieselschrauber.org/en                 Adresse 01: Motorelektronik       Labeldatei: DRV\059-907-401-V2.clb    Steuergerät-Teilenummer: 4G0 907 401 F    HW: 4G0 907 401   Bauteil und/oder Version: 3.0TDI EDC17  H37 0002                  Codierung: 1A25401A046601020800             Betriebsnummer: WSC 02311 785 00200               ASAM Datensatz: EV_ECM30TDI0114G0907401F 001002 (AU57)                        ROD: EV_ECM30TDI0114G0907401F.rod                       VCID: 264593CA59D226747B-8072 7 Fehlercodes gefunden: 5168 - Signal Höhengeber/Ladedrucksensor           P1592 00 [032] - unplausibles Verhältnis           Sporadisch - unbestätigt - geprüft seit letzter Löschung 5188 - Dieselpartikelfilter - Russbeladung zu hoch           P2463 00 [096] - -           Sporadisch - unbestätigt - geprüft seit letzter Löschung              Umgebungsbedingungen:                     Fehlerstatus: 00000001                     Fehlerpriorität: 2                     Fehlerhäufigkeit: 3                     Kilometerstand: 171456 km                     Datum: 2018.08.05                     Zeit: 17:05:54                     Motordrehzahl: 1592.00 /min                     Normierter Lastwert: 71.0 %                     Fahrzeuggeschwindigkeit: 49 km/h                     Kühlmitteltemperatur: 55 °C                     Ansauglufttemperatur: 31 °C                     Umgebungsluftdruck: 890 mbar                     Spannung Klemme 30: 14.040 V                     Verlernzähler nach OBD: 40                     P Flt Ld fac Ash Cor: 0.8500                     Differenzdruck Partikelfilter: 152 hPa                     Exh t Adap T Oxi Cat Ds: 616.6 °C                     Exh t Adap TP Flt Ds: 565.9 °C                     Abgasvolumenstrom im Partikelfilter: 333.9 m³/h                     Aktuelle Betriebsart_2-Bits 0-7: 0                     Aktuelle Betriebsart_2-Bits 0-7: 0                     Aktuelle Betriebsart_2-Bits 0-7: 0                     Aktuelle Betriebsart_2-Bits 0-7: 1 5245 - Geber für Kraftstoffdruck (G247)           P0192 00 [032] - Kurzschluss nach Masse           Sporadisch - unbestätigt - geprüft seit letzter Löschung 10065 - Luftmassenmesser (G70)           P0104 00 [032] - kein Signal           Sporadisch - unbestätigt - geprüft seit letzter Löschung 5268 - Geber 1 für Abgastemperatur (G235)           P0545 00 [032] - Kurzschluss nach Masse           Sporadisch - unbestätigt - geprüft seit letzter Löschung 5162 - Dieselpartikelfilter Differenzdruckgeber           P2453 00 [096] - unplausibles Signal           Sporadisch - unbestätigt - geprüft seit letzter Löschung              Umgebungsbedingungen:                     Fehlerstatus: 00000001                     Fehlerpriorität: 2                     Fehlerhäufigkeit: 3                     Kilometerstand: 171456 km                     Datum: 2018.08.05                     Zeit: 17:07:00                     Motordrehzahl: 0.00 /min                     Normierter Lastwert: 0.0 %                     Fahrzeuggeschwindigkeit: 0 km/h                     Kühlmitteltemperatur: 60 °C                     Ansauglufttemperatur: 34 °C                     Umgebungsluftdruck: 890 mbar                     Spannung Klemme 30: 12.880 V                     Verlernzähler nach OBD: 40                     Geber für Differenzdruck über Partikelfilter: Rohwert: 62 hPa                     Partikelfilter: Differenzdruck: 65 hPa                     Partikelfilter: Offset für Differenzdruck: -3 hPa                     Partikelfilter Differenzdruck dynamischer Offset: 0 hPa                     Außentemperatur: 25.0 °C                     Partikelfilter: Rußmasse gemessen: 59.49 g                     Partikelfilter: Rußmasse berechnet: 18.67 g 5189 - Partikelfilter Bank 1           P2002 00 [096] - Fehlfunktion           Sporadisch - unbestätigt - geprüft seit letzter Löschung              Umgebungsbedingungen:                     Fehlerstatus: 00000001                     Fehlerpriorität: 2                     Fehlerhäufigkeit: 3                     Kilometerstand: 171456 km                     Datum: 2018.08.05                     Zeit: 17:05:54                     Motordrehzahl: 1592.00 /min                     Normierter Lastwert: 71.0 %                     Fahrzeuggeschwindigkeit: 49 km/h                     Kühlmitteltemperatur: 55 °C                     Ansauglufttemperatur: 31 °C                     Umgebungsluftdruck: 890 mbar                     Spannung Klemme 30: 14.040 V                     Verlernzähler nach OBD: 40                     Außentemperatur: 24.3 °C                     Partikelfilter: Offset für Differenzdruck: -3 hPa                     Partikelfilter: Rußmasse gemessen: 34.07 g                     Partikelfilter: Rußmasse berechnet: 19.04 g                     Partikelfilter: Kilometer seit letzter Regeneration: 140491 m                     Partikelfilter Feldregeneration: Abbruchbedingungen-Bits 0-7: 0                     Partikelfilter Feldregeneration: Abbruchbedingungen-Bits 0-7: 0 Readiness: 0 0 0 0 0

Thank you in advance.

Best regards, Patrick.

Repair defects and https://community.dieselschrauber.org/en/viewtopic.php?t=29120 accordingly.

Best regards, Rainer.

dieselschrauber wrote:

Repair defects

"Thank you, but that's exactly the question: what could likely be defective based on the measured values? I can already imagine that if I go to the dealership, I'll just get a response like, 'The DPF needs to be replaced.'"

I just completed another test run and didn't receive a single error (duration approximately 50 minutes).

I was even able to initiate a forced regeneration while stationary. Overall, everything is fine now. I'm currently unsure about the next steps.

If it happens again or if I gain new insights, I will get back to you.

PS: Of course, I had already read the linked post beforehand.

Okay, I'm seeing an error code from the differential pressure sensor. This error may have caused other errors. I need to check, test, and it's likely that the sensor will need to be replaced.

That wouldn't be entirely unreasonable...

5268 - Sensor 1 for exhaust gas temperature (G235).
P0545 00 [032] - Short circuit to ground.
Sporadically - unconfirmed - checked since last deletion.


I would start by replacing the sensor, clearing the entries, and then performing a service regeneration.

StyLeZP wrote:

dieselschrauber wrote: Repair defects Okay, but that's exactly the question: what could likely be defective based on the measured values? I can already imagine that if I go to the dealership, I'll just get a response like "The DPF needs to be replaced." I just completed another test run and didn't receive a single error (duration approximately 50 minutes). I was even able to initiate a forced regeneration while stationary. Overall, everything is fine now. I'm currently unsure about the next steps. If it happens again or if I gain new insights, I will get back to you. PS: Of course, I had already read the linked post beforehand.

It's clearly stated in the Autoscan what's broken, so why aren't the corresponding things being checked?