DPF Touran replacement

Hi everyone,
I have an AFN engine in my T3 with a DPF, and I originally bought a VCDS to work on it.
Now, it's about my daughter's car, a Touran, 1.9 TDI, MKB: BLS. Engine mileage: 176185 km
After unsuccessful regeneration attempts, most recently towards 100% load, I replaced the DPF and the differential pressure sensor 10 days ago. Afterwards, I set the ash content to 0 and re-calibrated the sensor. I let the engine run for a few minutes, then performed diagnostics. Ash content: 0, Load: 9.9%. Subsequently, I drove approximately 15 km and performed diagnostics again. Ash mass 0 and load 0, to great joy.
After several days, re-analyzed, now 2% loading, Today re-analyzed, ash content still 0, loading coefficient 5.1%
Now, some things are just not coming out. So far, approximately 270 km of driving, mainly in the city. Although, I have reached speeds of up to 40 km per day.
My question: is this normal? Is the load gradually increasing and then the vehicle automatically regenerates back down in its normal cycle? Or is there a problem coming? I've read that this happens every 500-1000 km. At what approximate load does this start to happen, and how far does it then decrease? The timeframe seems so short to me.
Attach some files.
Thank you in advance for your responses.

Hello,

The load is how much soot is in the DPF.
Under appropriate load conditions, the value can self-reduce (passive regeneration).
The active regeneration process is initiated by your engine control unit (ECU) when the value exceeds a certain threshold. During the regeneration process, the Russ is burned.

What remains is the ash, which increases with the lifespan of the DPF (ash volume, ash mass).
Is it too high? Is the filter full of ash and needs to be replaced or cleaned?
DPF cleaning and function

Best regards, Rainer

Hey,
Thank you for the quick response and the link.
The process was essentially intentional, I was just surprised that the load increased so quickly after about 280 km. So it's correct, and the regeneration starts once a certain value is reached. I was just worried that something was going wrong. I will check it periodically in the coming weeks and hope to see a decrease in the load at a certain point. The mass/volume of the ash will, of course, eventually increase, but there is still time for that to happen.
I will provide an update in 2-4 weeks.

Best regards, Ralf

P.S. The DPF is new, from Ernst's company, that's why I entered 0 for the ash mass. The differential pressure sensor is the new one, both related to Bosch.

Quote:

The process was essentially intentional, I was just surprised that the loading increased so quickly after about 280 km.

Hi,

is normal. Regeneration starts, according to my memory, at around 40%. But I could also be wrong, please correct me if someone knows better, there are also many posts about regeneration here in the forum.

Best regards, Rainer

Hey,
Touran, manufactured in 2006; 1.9 TDI; 105 hp, Engine Code: BLS; approx. 177TSD
I wanted to get in touch again.
After our vacation, I wanted to have my daughter's Touran TDI checked on Friday. In the evening, you informed me that the DPF lamp was on, which is a serious issue. I regularly checked the following values, which were 0% ash, indicating that it was new, followed by loads of 2%; 5.1%; !2.2%; 21.2; 27.2%. On Friday, the figure will be 41.4%.
OK, light on, now he should be recovering.
Time since DPF regeneration was approximately 1000 km, nothing happened. Then today, my daughter drove on the highway at 2400 RPM, and lo and behold, after about 8 km, the light came on. She then drove for approximately 15 minutes.
Just finished, ash 0, load 9.1%, seems to be working, I just thought it would be heading towards a load of 0. Is this normal, or should I have driven for longer?
I have also attached the scan and data. I think I should take some time to look at the measurement logs. Thank you.

Best regards, Ralf

Hello...
Without me really knowing, but: Didn't there used to be a DPF warning light in the early days of the VW DPF that indicated the upcoming regeneration, and then you had to drive for 40 km with >2500 rpm without interruption, etc. And where, at least with the Passat and the VW Touareg, there was an additive - SATACEN 25?
SG
Manfred

alevuz wrote:

Hello... Without me really knowing, but: Didn't there used to be a DPF warning light in the early days of the VW DPF that indicated the upcoming regeneration, and then you had to drive for 40 km with >2500 rpm without interruption, etc. And where, at least with the Passat and the VW Touareg, there was an additive - SATACEN 25? SG Manfred

The warning light appeared on the Audi A3 with engine code CFFB after the emissions update (again)?

As long as the regeneration intervals are okay and functioning properly, I don't see any need for action.

Hi, Rainer

Hey,
Thank you, then I feel reassured.
Since we have been in Scandinavia for a while, I was concerned that my child wouldn't know what to do in case of a problem.
I'll check with a friend to see if he can read the control unit every 4 weeks and keep me updated.
Thank you again.

Best regards, Ralf

Hey,
My fears have come true; we in Scandinavia, Touran, the daughter, is crazy.
Touran, 1.9 TDI, Year 2006, BLS, Approximately 177,500 km, DPF new since approximately 2,000 km, as well as pressure sensor.
First, turn on the DPF light, then the bulb, then the engine light.
My friend diagnosed yesterday, Bank 1, P2002-00 DPF malfunction. The first regeneration seems to have worked, but the second one didn't, and it's also only 400 km away.
Ash 0, Load 47.7 %
I probably made a mistake, and I have to admit it: Here's the explanation:
In November, the head was renewed, as water was always leaking out from above the second light bulb, outwards. A new head was planned. Unfortunately, the water continued to leak, leading to suspicion of a hairline crack. In December, the new head from AMC was mounted, the valves were cleaned and adjusted, the bearings were replaced, and the INA hydros were renewed. The pump elements were also re-sealed, and the basic settings were adjusted, as the head had been newly installed. Actually, everything is in the green zone.
WARNING: Because the old crankshaft had marks from the bearings and the bearings were new, I installed a different, very good crankshaft, also from a BLS, with the same part number. However, since yesterday, I know that there are 2 crankshafts for the BLS, and they must not be confused, with and without DPF. According to the VW program, there is only ONE exact crankshaft, but 2 crankshafts for the same engine. I should have the 038 109 101 AH, but I don't know. I think here, the mechanical actuation is colliding with the data from the control unit.
The problem started 6 weeks after the head was mounted. The DPF light is on, ash content is 48g, load is approximately 38%, which is actually okay, but it wasn't regenerating. So, a manual regeneration was attempted, but unfortunately, it failed 3 times. Then, a new DPF and a new pressure sensor were installed and calibrated. After 5 weeks, the DPF light was on, but after being read out, the ash content was 0g, and the load was 41.4%. The lamp stopped working after 2 days, because it was used for short trips, then on the highway, and after a few kilometers, the lamp stopped working, indicating an error, with 0g of ash and a 9.1% load.
After 3 weeks, I'm back, unfortunately with the full program. Autoscan has been shipped to my friend today. Error P2002-00, DPF malfunction, Ash 0g, Load 47.7%.
I hope this helps you. However, my suspicion is that there's a major problem with the camshaft. I hope they can remove the valve cover today and check if they can read the part number of the camshaft. I'm really in a difficult situation and I'm considering taking the ferry to DE on Thursday to replace the camshaft, re-tighten the bolts and adjust the components. This is insane. Then, a few days later, back up again, Crazy.

Best regards, Ralf
P.S. We have had the car for about 2.5 years. When the lamp first came on after the DPF replacement, I thought it had never been on before, especially during regeneration, and that's when the problem started, I think.

Hi,
It is possible that the engine with a particulate filter requires a different camshaft in order to achieve after-injection with the PDE's.
A person's will is their heaven, but I advise against remote diagnoses, and instead, to address the issue calmly after the vacation. It's not just about the NW exchange, but also about testing the particulate filter and potentially further repairs. Until then, the vehicle must remain stationary, otherwise, no service regeneration will be possible. A rental car for two weeks doesn't cost a fortune.
hg
Herbert

Hello,

Before I remove the camshaft, I would start a regeneration using VCDS and check the temperatures before and after the DPF. If the DPF temperature is 15°C while the car is running and a DPF error is logged, it is unlikely to be due to the crankshaft.

Can also be logged and uploaded here.

There are also several other reasons why regeneration fails. Specifically, the values of the temperature sensors on the DPF would be of interest.

Best regards, Rainer

Hello Rainer,

I've only had a bad feeling about the camshaft for a few days, and then two days ago, I read something from the parts suppliers that it's important not to install the wrong camshaft.

Subsequently, I checked the VW program, and it confirmed that there is indeed one wave for the BLS. My suspicion was that the cam for the rocker arms must have a different angle, meaning that the injectors are actuated earlier or later, but the control unit, due to the engine speed and the crankshaft-camshaft sensor, controls the pump elements, and this doesn't work together during regeneration.
"Of course, checking the sensors and the regeneration cycle is important. The DPF has only been installed for about 1500 km. I will be in Sweden until the end of August, and I will probably have to return home for 1 week because of this. Otherwise, it won't work, unfortunately." Thank you very much.

I was just thinking about the camshaft because otherwise, everything was working fine until 5 weeks after the head replacement, and that would be the only part that might not fit at that time. All speculations.
My friend is probably going to remove the valve cover soon in order to possibly see the part number. VW cannot provide further assistance, referring to part number, does not match, invalid.

Best regards, Ralf

Hello,
Continuing would be risky, as if the M-Stg. wants to regenerate, it will inject more fuel to reach higher temperatures (600-700°C). If this doesn't work, the DPF loading will increase dramatically due to the increased fuel amount. If the value is too high, it cannot regenerate because there is a risk of fire. However, the DPF indicator should light up beforehand (which means that the regeneration must be carried out by the owner through a longer drive). If this also doesn't work, the second check is the engine check. (This means regeneration can only be performed with a tester) From there, things will proceed quickly.

As mentioned before, I would start the regeneration with the tester and monitor the temperature sensors. They should reach, or exceed, 600°C. Furthermore, a faulty intake system could be the cause.
Otherwise, it's probably really the camshaft.

Best regards, Dago

Hello

Dagomanu wrote:

Hello, Continuing would be risky, as if the M-Stg. "I want to regenerate, so inject more fuel to reach the higher temperatures (600-700°C)." ... As mentioned before, I would start the regeneration with the tester and monitor the temperature sensors. They should reach, or exceed, 600°C. Furthermore, a faulty intake system could be the cause. Otherwise, it's probably really the camshaft.

Exactly

See also:
The DPF does not regenerate

Best regards, Rainer

Sorry for my negative objection:

I would definitely not be driving anymore. Your camshaft simply doesn't have the profile pressure needed to build up the required post-injection in the PD element. The MSG doesn't know about this either. Your problems will only get worse. Because the PD elements are being activated, and therefore, something will definitely come out, which, however, due to the spray pattern and amount, neither helps nor is beneficial for the regeneration.

The correct camshaft is the only way.

I believe that VW only has one type of filter left, because then everyone would have the right one for DPF engines. That doesn't create a disadvantage for engines without a DPF from their perspective.

The subsequent investigation did not go well for the PD.

Hello everyone,

Thank you for the quick responses. Touran, 2006, 1.9 TDI BLS, 177TSD
A sailing trip would have been the right way to go, but we were 1000 km away. The car, of course, was not driven any further.
Following the post by matthiasTDI96, my suspicion (as described above), and with the really nice contact from Mr. Bartl from BK Motorentechnik, it became clear that the camshaft was incorrect. So, I ordered a camshaft set, shipped it back to Germany, and installed it yesterday.

Then onto the highway, the Touran wasn't really regenerating, load at 47.7%, so onto the parking lot, emergency regeneration started, and insane, no more than 6-8 km and the load was 0%. Now the temperatures also seemed right, sometimes over 700 degrees. Then about 12 km on the country road, finished, ash 0%, load 0%, no more error entries, lights off. Thank God, I've learned again. It was actually due to the wrong camshaft, which caused a lot of ash to fall on my head.

My saying: Whoever doesn't learn something new in old age, has reached the end of their life.

Best regards, Ralf