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DPF/EGR Repairs and Solutions

From around 2008 -2009 most diesel vehicles were fitted with a DPF (Diesel Particulate Filter) designed to reduce exhaust gas emissions by capturing the miniscule particle matter that is expelled from a vehicles exhaust.

By way of a specific catalytic filter fitted after the turbo and before the mid-section of the exhaust system, this filter is able to capture the soot that is created after the diesel fuel is burnt in the engine. A combination of carbon and nitrogen oxide (Nox) create highly toxic and poisonous pollutants which are the make-up of this soot. By using a very specific type of catalyst material and design these particles are attracted to the material used in this filter and as a result capture 90% of this soot matter. If that makes sense!

Over time this soot starts to clog up the small channels of the DPF and cause reduced power symptoms or even safe / limp mode. This mode is designed to protect the engine from any catastrophic damage. Normally a diesel engine is programmed to regenerate the DPF after a specified mileage or when a measured amount of soot is calculated by various sensors and software parameters written in the ECU. However, this regeneration process can fail for a number of reasons, the most common being short / stop / start journeys where the engine is unable to get up to full operating temperature required to enable the regeneration procedure of burning off the accumulated soot particles. Other contributory factors such as poor fuel quality, faulty sensors, intake problems, turbo failure, EGR valve (Exhaust Gas Recycling Valve) faults etc can also cause the regeneration process to fail.

Some vehicle manufacturers create a mileage specific lifespan for a DPF which will then require the costly replacement of a filter once this set mileage has been reached regardless of the physical condition of the filter itself.

Fortunately, we are an independent DPF specialist that can accurately diagnose your DPF problems and any underlying faults that have caused your DPF Light to appear. You may be experiencing severe EGR problems, INJECTOR issues or even a dramatic loss of power. With the aid of TUNAP AUTOMOTIVE CHEMISTRY we can offer a cost-effective solution without involving costly repair bills.

We are able to offer various preventative procedures to allow your vehicle to operate efficiently and safely without any further costly repairs or unnecessary replacement parts.

Diesel Particulate Filter (DPF) Video Gallery


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Vauxhall /Opel Insignia 2.0 CDTi



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EGR Diagnostics and Solutions

What is an EGR valve and what's its purpose in an engine?

Here is a simplified explanation of what an Exhaust Gas Recirculation Valve is designed to do!

As far back as 1973 vehicle manufacturers were required by law to start to reduce the amount of particle soot matter from a diesel / gasoline engine. This was a very complex and technically challenging task to develop a solution. In internal combustion engines exhaust gas recirculation (EGR) is a nitrogen oxide (NOx) emissions reduction technique used in petrol/gasoline and diesel engines. EGR works by recirculating a portion of an engine's exhaust gas back to the engine cylinders.

The EGR valve was designed to reduce exhaust NOx gas by diluting the O2 in the incoming air stream and provide gases inert to combustion to act as absorbents of combustion heat to reduce peak in-cylinder temperatures. NOx is produced in high temperature mixtures of atmospheric nitrogen and oxygen that occur in the combustion cylinder, and this usually occurs at cylinder peak pressure.

The very early EGR valve system was developed to recycle 5% -15% of exhaust gases without affecting vehicle output, performance and economy. However, this technology did not come without problems. Recycling the exhaust gas meant effectively reburning particulate deposits mixed with oil in the engine and thereby causing deposits of carbon to accumulate and effectively cause premature engine wear. Not an ideal situation as it resulted in reduced power and significant loss of economy. Today's modern diesel engines with new updated EGR systems now recycle up to as much as 80% of exhaust gases incorporating the introduction of DPF and AdBlue technology to reduce emissions even further. Petrol engines now have PPFs fitted which are the equivalent of a DPF.

Needless to say, carbon deposits still cause the majority of EGR valve failures and an even greater volume of replacement/repairs are required due to the increased percentages of recirculated particulates.

That’s where Octane Tuning is able to assist you. By carrying out a detailed and in-depth diagnostic analysis of the engine, we are able to pinpoint the root cause of the failure and advise accordingly.

With our custom written solutions, we are able to adapt the EGR cycle within the ECU preventing further loss of power and reduced economy and unnecessary expensive repair bills. For newer vehicles still under manufacturer's warranty we can offer our specialist EGR Cleaning Service using TUNAP Automotive Chemistry approved by all the major marques.

EGR Cleaning - Before and After

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Call: 01620 490 041

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