Mk6 DPF failure

[Tdimrtwo]

I recently bought a 2011 JSW CJAA, runs OK but has a check engine light on with P2002, P0401 and a sooty tailpipe. I needed daily transportation when I bought it, so I’ve been driving it a lot, and I don’t know how long CEL was on before I bought it. This is my first experience with a Mk6 and CJAA, so I’m trying to piece together what’s going on. If I understand what I’m reading here, I have a broken DPF, a clogged EGR, and depending on how long it’s been driven like this, possibly a bad cat. It makes sense to me to do a total delete as inexpensively as I reasonably can. If I understand correctly, the best approach is to get a downpipe and a egr block-off plate from one of several manufacturers, then do a delete tune from tunezilla. Am I good so far? Worst case, I may also need do a cat delete. Rawtek offers a nice one-stop shopping package, but it seems more expensive. Best price I’ve found is MecEvo, but I haven’t heard much about their quality. Anyone have any experience with them? What else will I need to do this project?

 

[Tuheeden]

Here is everything you need:

CBEA/CJAA DPF info

Mods, please make this a sticky so I can easily point people here. When (not if) your CBEA or CJAA car flags the DTCs P2002, P0401, and sometimes P240F, and your car will have sooty tailpipes, YOUR DPF HAS FAILED. It is BROKEN. It cannot be cleaned. It will need to be replaced. This is the...

forums.tdiclub.com

 

[Tdimrtwo]

Thanks Tuheeden, that’s the parts I would need to replace a broken DPF. However, what I’m actually trying to do is delete the DPF, Egr, and catalytic converter, so I’m trying to figure out what’s needed for that procedure. Any help or direction would sure be appreciated.

 

[Tuheeden]

Thanks Tuheeden, that’s the parts I would need to replace a broken DPF. However, what I’m actually trying to do is delete the DPF, Egr, and catalytic converter, so I’m trying to figure out what’s needed for that procedure. Any help or direction would sure be appreciated.

Ahh. Yes Rawtek is the premium option. Take a look at FlowDirekt for about half the price (it's 2.5in where Rawtek is 3in). I strongly recommend a Catalytic converter as it really cuts down on diesel smell. And I like a resonator if you drive a lot of highway miles.
The exhaust kit is the only hardware you need BUT you also need a tune to go with it (keep in mind that modifications to the emissions system is illegal for use on public roads and you may not pass inspections in your local area)
There are a lot of posts on tunes but for the Common Rail I still like Tunzilla, stage 2 for the "basic" delete. I'm sure others will weigh in.
The install is quite EZ: remove everything from the turbo back to the back coupler, bolt on new exhaust, tune and go!

 

[Tdimrtwo]

Wow, thanks again Tuheeden, That’s exactly the information I was looking for. So a Flowdirect dpf delete down pipe, an Egr blockoff plate, and a tunezilla. Keep the existing cat, And maybe a resonator if it’s too loud on the highway.

 

[Mozambiquer]

Wow, thanks again Tuheeden, That’s exactly the information I was looking for. So a Flowdirect dpf delete down pipe, an Egr blockoff plate, and a tunezilla. Keep the existing cat, And maybe a resonator if it’s too loud on the highway.

This is the best option, and if you get the Tunezilla before the end of this month, it's on sale. I am a dealer and can get an even better price if you want.

 

[Tuheeden]

Wow, thanks again Tuheeden, That’s exactly the information I was looking for. So a Flowdirect dpf delete down pipe, an Egr blockoff plate, and a tunezilla. Keep the existing cat, And maybe a resonator if it’s too loud on the highway.

You will NOT keep the existing catalytic converter, when you order the downpipe you can request a high flow catalytic converter. The exhaust kit will come with the block off plate

 

[Tdimrtwo]

Mozambiquer,
I messaged you about tunezilla, can you read it and reply?

 

[Tdimrtwo]

Trying to explore all my options. If I gut my existing Dpf, rather than buy a new downpipe, what other hardware will I need? From what I’ve read, I’ll need at least an egr block off plate, but I’m not to sure about the cat(s). Can I:
1. keep the old cat(s)
2. delete the old cat
3. replace with a new high flow catalytic converter

My goal is to end up with a reliable, economical car that I can daily drive. I’m not necessarily trying for huge power gains, although a few more ponies would be great, as long as I can still achieve the fuel economy that drew me to a tdi in the first place.

 

[Tdimrtwo]

Trying to explore all my options. If I gut my existing Dpf, rather than buy a new downpipe, what other hardware will I need? From what I’ve read, I’ll need at least an egr block off plate, but I’m not to sure about the cat(s). Can I:
1. keep the old cat(s)
2. delete the old cat
3. replace with a new high flow catalytic converter

My goal is to end up with a reliable, economical car that I can daily drive. I’m not necessarily trying for huge power gains, although a few more ponies would be great, as long as I can still achieve the fuel economy that drew me to a tdi in the first place.

 

[pkhoury]

I would
1. delete old cat
2. keep old cat in the shed
3. replace with straight pipe

What he said. Losing hardware from running over a pothole will eliminate A LOT of problems in the future.

 

[Tdimrtwo]

Thanks for the advice.
Would it change your recommendation if I mentioned that I also want a quiet car that doesn’t smoke or have a strong diesel smell? My understanding is that deleting the cat and straight piping will result in a loud, smoky and stinky car. And to add one more item to the unrealistic expectations category, i need to do it as cheaply as i can. I’ve bought two cars in the last two months, and I’m pretty strapped for cash right now.

 

[Tdimrtwo]

Thanks turbodieseldyke, thats exactly my plan. I have an acetylene torch, a wire welder and some of the skills needed to operate them. I’ll try to cut three-sides of a square, bend it back, hammer out the ceramic substrate and weld it back afterwards.

I believe I will still need an Egr blockoff plate, can I buy that separately?

 

[GTD170]

I deleted everything that you are thinking of and on my mk6 golf my cat/dpf was together in one unit in the downpipe so a downpipe alone should cover the cat/dpf delete. Then get an egr delete kit and obviously a tune.

Im in the UK so im not sure if my setup was different to the US in regards of emission standards but it might be worth checking.

Check out darkside developments...
I paid £450 for a downpipe £150 egr delete kit and then got a tune.

 

[Tdimrtwo]

Great food for thought. I think I’ll try gutting the Dpf, blocking off the egr and doing a tunezilla. If I don’t like the way it runs or sounds, I can do more later.

 

[x1800MODMY360x]

Great food for thought. I think I’ll try gutting the Dpf, blocking off the egr and doing a tunezilla. If I don’t like the way it runs or sounds, I can do more later.

You also need to gut the LNT as well or you will have problems down the road as well.

 

[Tdimrtwo]

What’s an LNT? As turbo asked, is it the cat after the dpf? Is there an easy way to straight pipe it? I agree turbo, I had to drive my daughter’s Prius back from Houston when thieves stole her cat, loudest Prius ever.

 

[oilhammer]

LNT = Lean NOx Trap.... it is the deNOx catalyst in the middle of the car, after the DPF assembly.

 

[Tdimrtwo]

thanks, can I just gut it like I’m planning to do to the Dpf? It’s a 2011 with 280k miles, I don’t see ever returning it to stock. Texas just eliminated vehicle inspections and the place I live doesn’t do emissions testing so I’m pretty sure it’ll never go back.

 

[Tdimrtwo]

Mozambiquer,
Can I buy a tune from you? Tunezilla says they can authorize 10% off if you open a case with a particular code, I sent you a message.

 

[Mozambiquer]

Mozambiquer,
Can I buy a tune from you? Tunezilla says they can authorize 10% off if you open a case with a particular code, I sent you a message.

Got your message replied to. I can still do the 15% for you.

 

[Francobenz]

You should probably remove the existing hardware and sell it. An option you can also check for is the OEM downpipe from a MK5 with a BRM engine. That way you have an integrated cat.

 

[Tdimrtwo]

Ok thanks. My car is a daily driver/ family vehicle. I want to gut my Dpf and cat, and delete the egr to make it reliable while maximizing mileage and drivability and minimizing my cost. I don’t want to end up with a loud, smoky car, and I’m not primarily looking for power gains. Which tune would best meet my goals? The advertised HP increases as the tunes go up, so fuel use should increase as well, depending on driving style.

 

[GTD170]

Ok thanks. My car is a daily driver/ family vehicle. I want to gut my Dpf and cat, and delete the egr to make it reliable while maximizing mileage and drivability and minimizing my cost. I don’t want to end up with a loud, smoky car, and I’m not primarily looking for power gains. Which tune would best meet my goals? The advertised HP increases as the tunes go up, so fuel use should increase as well, depending on driving style.

You just need a basic tune to delete and give a little boost in performance now that the car will be able to breathe better with the deleted dpf/egr etc.

Generally tunes go like this to my knowledge....

Stage 1 - dpf/egr/cat delete + tune.
Stage 2 - (stage1) + upgraded air intake, coolant rad, intercooler + tune.
Stage 3 - (stage2) + upgraded fuel pump, injectors, ported head, cams, turbo + tune.

 

[Tdimrtwo]

Thanks, I should’ve been more specific in my question. What I actually want to know is which Tunezilla tune will provide me the best economy.
Tunezilla offers:
Stage 0.5
Stage 1
stage 2
Stage 3
Stage 4
Custom tune

Up to stage 2 can be done on stock mechanicals, while stage 3 and above require supporting mods.
acvording to tunezilla, I’ll probably get my best economy with stage 0.5 and a light foot.
Does anyone have any more specific experience?

 

[Mozambiquer]

Thanks, I should’ve been more specific in my question. What I actually want to know is which Tunezilla tune will provide me the best economy.
Tunezilla offers:
Stage 0.5
Stage 1
stage 2
Stage 3
Stage 4
Custom tune

Up to stage 2 can be done on stock mechanicals, while stage 3 and above require supporting mods.
acvording to tunezilla, I’ll probably get my best economy with stage 0.5 and a light foot.
Does anyone have any more specific experience?

Stage 0.5 is what I've found to be best for fuel economy. Stage two can get the same, but it takes more self control...