DPF Replacement: Volkswagen Touran Repair

Hi everyone,
I personally have an AFN engine in my T3 with a DPF, and that's why I bought VCDS in the first place.
Now we're talking about my daughter's car, a VW Touran, 1.9 TDI with engine code BLS and mileage of 176,185 km.
After unsuccessful regeneration attempts, with the DPF nearing 100% loading, I replaced the DPF and the differential pressure sensor about 10 days ago. Afterwards, I reset the ash content to zero and calibrated the sensor. I let the engine run for a few minutes, then checked the readings: ash content was 0, and loading was 9.9%. Then, I drove approximately 15 km and checked the readings again. The ash content was 0, and the loading was 0, which was very pleasing.
After a few days, re-analyzed; now with 2% moisture content. Analyzed again today; ash content still 0%; loading coefficient 5.1%.
"Now, some things don't make sense to me. I've driven approximately 270 km so far, mostly in the city, with a daily average of up to 40 km."
My question is: Is this normal? Does the particulate filter loading gradually increase, and then does the vehicle automatically regenerate to reduce it during a normal driving cycle, or is there an upcoming problem? I've read that this supposedly happens every 500-1000 km. At what level of loading does this approximately occur, and how much does it decrease afterwards? The regeneration period seems quite short to me.
Please attach some files.
Thank you in advance for your answers.

Hello,

The loading refers to the amount of soot in the DPF (Diesel Particulate Filter).
Under certain load conditions, the value can decrease again on its own (passive regeneration).
The active regeneration process starts your engine control unit (ECU) when the value exceeds a certain threshold. During regeneration, soot is burned off.

What remains is the ash, and the amount of ash (both in volume and mass) increases over the lifespan of the DPF.
If the pressure is too high, the filter will be full of ash and needs to be replaced or cleaned.
verschandeln and check the DPF function.

Best regards, Rainer.

Hey,
Thank you for the quick response and the link.
Basically, I was aware of the process, but I was surprised that the load increased so quickly after about 280 km. So, that's correct, and the regeneration starts from a certain value. I was just worried that something might be wrong. I will check it periodically in the coming weeks and hope to see a decrease in the load at some point. Of course, the ash mass/volume will eventually increase, but there's still time before that happens.
I'll give you an update in 2-4 weeks.

Best regards,
Ralf

P.S. The DPF is new, from the company Ernst, which is why I entered a value of 0 for the ash mass. The differential pressure sensor is also new, and both were sourced from Bosch.

Quote:

The process was basically known to me, I was just surprised that the load increased so quickly after about 280 km.

Hi,

is normal. Regeneration starts, according to my memory, at around 40%. However, I might be mistaken, so please correct me if someone knows better. There are also many posts about regeneration here in the forum.

Best regards, Rainer.

Hey,
Touran, year 2006; 1.9 TDI; 105 hp, engine code: BLS; approximately 177,000 kilometers (or miles).
I just wanted to follow up again.
After our vacation, I wanted to check the diagnostic data of my daughter's Touran TDI one last time on Friday. In the evening, she told me that the DPF light was on – a shock! At regular intervals, I had read out the following values: Ash content (0, since it's new), then loading levels of 2%; 5.1%; 12.2%; 21.2; 27.2%. On Friday, it was 41.4%.
"Okay," I thought, "lamp on, now it should start regenerating."
"Approximately 1000 km have passed since the DPF was regenerated, and nothing happened. Then, today, my daughter drove onto the highway, reaching 2400 RPM, and lo and behold, after about 8 km, the light went out. She then drove back for another approximately 15 minutes."
Just read the data: Ash content is 0%, loading is 9.1%. It seems to be working, but I thought the loading would decrease towards 0. Is this normal, or should it have been run for a longer time?
Habe noch den Scan und Daten angehangen. Ich glaube, ich muß mich mal mit den loggen der Messwerte befassen. Thank you all.

Best regards,
Ralf

Hello...
Okay, I'm not an expert, but: Didn't the early VW DPF systems have a warning light that indicated an upcoming regeneration process? And then you had to drive for 40 km at >2500 rpm without interruption... Also, wasn't there an additive used, at least in the Passat and BLE Touareg, called SATACEN 25?
Sure thing! Please provide the German text you would like me to translate into English. I will only provide the translation without any explanations.
Manfred.

alevuz wrote:

Hello... Okay, I'm not really an expert, but: Didn't the early VW DPF systems have a warning light that indicated an upcoming regeneration process? And then you had to drive for 40 km at >2500 rpm without interruption... Also, wasn't there an additive used, at least in the Passat and BLE Touareg, called SATACEN 25? Sure thing! Please provide the German text you would like me to translate into English. I will only provide the translation without any explanations. Manfred

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

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

Best regards, Rainer.

Hey,
Okay, then I'm relieved for now.
Since we're going to be in Scandinavia for a while, I was concerned that my child wouldn't know what to do if they encountered any problems.
I'll check with a friend to see if he can read the engine control unit every 4 weeks and keep me updated.
Thank you again.

Best regards,
Ralf

Hey,
My fear has come true; the Touran belonging to my daughter is malfunctioning here in Scandinavia.
Touran, 1.9 TDI, year of manufacture 2006, engine code BLS, approximately 177,500 km mileage, DPF (Diesel Particulate Filter) replaced about 2,000 km ago, as well as the pressure sensor.
First the DPF light came on, then the glow plug indicator, and finally the engine warning light.
My friend's car read a code yesterday: Bank 1, P2002-00, indicating a DPF malfunction. The first regeneration cycle seemed to work, but the second one didn't. It also only has about 400 kilometers on it.
Ash content: 0%, Loading: 47.7%
I probably messed something up, and I have to admit it; here's the explanation:
In November, the cylinder head was replaced because water was constantly leaking out from above the second spark plug, towards the outside of the head. Unfortunately, water continued to leak, suggesting a hairline crack. At the end of December, a new cylinder head from AMC was installed, and the valves were cleaned and re-lapped. New bearings were fitted, and the INA hydraulic lifters were replaced. The pump components were resealed, and a basic adjustment was performed since the cylinder head was new. Overall, everything seems to be in good condition now.
ATTENTION: Because the old camshaft had wear marks on the bearing surfaces and the bearings were new, I installed a different, very good camshaft, also from a BLS engine, with the same head number. However, since the day before yesterday, I've learned that there are two different camshafts for the BLS engine, which must not be mixed up, presumably one with and one without a DPF (Diesel Particulate Filter). According to the VW software, only ONE specific camshaft is listed, but there are actually TWO camshafts for the same engine. I should have the 038 109 101 AH part number, but I'm not sure. I think there's a conflict here between the mechanical operation and the ECU data.
Six weeks after the head replacement, the problem started: the DPF light came on, with 48g of ash and a loading level of approximately 38%, which is actually okay, but it wasn't regenerating. So, I tried a forced regeneration, unfortunately unsuccessfully three times. Then, a new DPF was installed along with a new pressure sensor, which was calibrated. After five weeks, the DPF light came on again. When checked, there was 0g of ash and a loading level of 41.4%. The light didn't go off after two days due to short trips. Then, I drove briefly on the highway, and after a few kilometers, the light went out. When checked, there was 0g of ash and a loading level of 9.1% – which seemed great.
After 3 weeks, it's back on again, unfortunately with the full program. My friend sent me the diagnostic scan results today, and the error code is P2002-00, indicating a DPF malfunction. The ash content is 0g, and the loading is 47.7%.
I hope this helps you all, but my suspicion is that the camshaft is the problem – a complete disaster. I hope they take off the valve cover today and check if they can read the part number of the shaft. I'm really stressed right now and considering taking the ferry to Germany on Thursday to replace the camshaft, re-install new screws, and adjust the timing elements – it's crazy. And then a few days later, coming back up again – also crazy.

Best regards,
Ralf
P.S. We've had the car for about 2.5 years. When the light first came on after a DPF replacement, I thought it was strange because I didn't think it had ever been on before. It seemed to be triggered during regeneration, which makes me think that's when the problem started.

Hi there,
It's quite possible that the engine with a particulate filter requires a different camshaft to achieve the post-injection process using common rail injectors.
"Man's will is his heaven," but I advise against remote diagnoses; instead, address the issue calmly after your vacation. It's not just about replacing the NOx sensor, but also about inspecting the particulate filter and potentially performing further repairs. Until then, it's essential to avoid using the vehicle, otherwise, even a service regeneration won't be possible. Renting a car for two weeks doesn't cost that much.
hg
Herbert.

Hello,

Before removing the camshaft, I would initiate a regeneration process using VCDS and observe the temperatures before and after the DPF. If the DPF temperature is 15°C while the car is running and a DPF error code is logged, it's less likely to be related to the camshaft.

You can also log it and upload it here.

Besides these, there are other reasons why the regeneration process might fail. In particular, the readings from the temperature sensors on the DPF would be interesting to examine.

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 from parts suppliers that it's important not to install the wrong shaft.

After that, I checked the VW program and it confirmed that there is a specific camshaft for the BLS engine. My assumption was that the camshaft lobe for the rocker arms must have a different profile, meaning that the injectors are activated earlier or later. However, the engine control unit controls the pump elements based on engine speed and crankshaft/camshaft sensor data, and this doesn't work well during regeneration.
Die Überprüfung der Sensoren wäre natürlich wichtig, bzw. die Regenerationsfahrt. Der DPF ist ja erst ca. 1500 km verbaut. Ich bin noch bis Ende August in Schweden, werde wohl deswegen für 1 Woche zurück nach Hause fahren müssen. Sonst wird das nichts, leider. Danke First of all.

The camshaft came to mind only because everything else seemed to be working fine until 5 weeks after the cylinder head replacement, and the camshaft would be the only part that might not fit properly. It's all speculation.
My friend is probably going to remove the valve cover right away to see if he can find a part number. VW can't help me; they just refer me to the part number, which doesn't match or isn't available.

Best regards,
Ralf

Hello,
I would be cautious about continuing to drive, because if the engine control unit wants to initiate regeneration, it will inject more fuel to reach higher temperatures (600-700°C). If this doesn't happen, the increased amount of fuel will significantly increase the DPF loading. If the value is too high, regeneration becomes impossible due to the risk of fire. However, before that, the DPF warning light should illuminate (which indicates that the owner needs to perform regeneration through a longer drive). If this also doesn't work, the next step is an engine check. (This means regeneration can only be performed with a diagnostic tool). From there, things can escalate quickly.

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

Best regards,
Dago

Hello.

Dagomanu wrote:

Hello, I would be cautious about continuing to drive, because if the catalytic converter wants to regenerate, it will inject more fuel to reach higher temperatures (600-700°C). ... As mentioned before, I would start a regeneration cycle with the tester and monitor the temperature sensors. They should reach or exceed 600°C. Furthermore, a faulty intercooler system could be the cause. Otherwise, it's probably the camshaft that's causing the problem.

Exactly .

See also:
DPF not regenerating

Best regards, Rainer.

I'm sorry for my negative comment.

I definitely wouldn't drive it anymore. Your camshaft simply lacks the profile to generate the pressure needed for the required post-injection in the PD element. The engine control unit (ECU) is unaware of this. Your problems will only get worse. Because the PD elements are being activated, and something will certainly come out of them, but that will likely neither help nor be beneficial for regeneration, given the spray pattern and amount.

The correct camshaft is the only way to go.

I guess Volkswagen only offers one type of engine now, because then all engines would have the flanges for Diesel Particulate Filter (DPF) systems. From their perspective, this wouldn't be a disadvantage for engines without a DPF.

The post-injection procedure didn't really suit him.

Hello everyone,

Thank you for the quick responses. Touran, 2006, 1.9 TDI BLS engine, 177,000 km (or miles).
A truck journey would have been the right way to go, but we were located 1000 km away. Of course, the car wasn't driven any further.
Following matthiasTDI96's post, my suspicion (described above), and the very helpful contact with Mr. Bartl from BK Motorentechnik, it became clear that the camshaft was incorrect. So, I ordered a new camshaft kit, sent it back to Germany, and had it installed yesterday.

Then onto the highway, but the Touran wasn't really regenerating properly. The load was at 47.7%, so I pulled over to the parking lot, initiated a forced regeneration, and it was incredible – after only 6-8 km, the load had dropped to 0%. Now the temperatures were also high, exceeding 700 degrees in some areas. Then I drove about 12 km back on country roads. After checking, the ash level was 0%, the load was 0%, and there were no more error messages stored, and the warning lights were off. Thank goodness, I learned something again. It really was due to the wrong camshaft; I feel foolish now.

My motto: Those who stop learning in old age have reached the end of their life's journey.

Best regards,
Ralf