Need help!! Anyone running dpf delete with stage 2 malone

Coffeemade

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Huh I was under impression Les was a dealer for Malone. He has flashed mine with Malone tunes more than a couple times.
I guess you are right (just checked his website), now here's the question, did he work on your car or was it another shop?
 

aullein

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Does anyone know how to tell if the DEF injector is clogged besides just looking at it And possibly seeing discolor. I'm guessing it's gonna be black regardless if it was being used or not just from the soot passion through
 

aullein

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I guess you are right (just checked his website), now here's the question, did he work on your car or was it another shop?
Curious to see what your DEF injector looks like. I never heard back from the shop today. I'll post as soon as I hear something.
 

Coffeemade

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So just an FYI, 15k on the tune and my DEF light came on, tank was full. The fix at the moment was flash it back to stage 2 with DPF (my first tune). Put ECU back in the car, turn the car on to accessory mode, wait 1 minute, then start the car. Turn it off and then turn it back on and light was gone. Flashed it back to Stage2 without DPF.

So yes this is just a work around at the moment, but it worked. I know when Malone gets back he will address this.

I am happy with the tune, being the second car in the US with this tune, I know there will be quirks, but I had a malone tuner install and that works in the shop that did all my exhaust work. Top quality!

The DEF injector needs to be installed in the exhaust and mine isn't clogged and doesn't have any issues.
 

aullein

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Hey coffee was that the DEF light or was that the adblue light that signaled a countdown like you mentioned before?? Or am I talkin about the same light/warning?
 

aullein

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Thanks Loki. Wow then he cleared the light without even starting the engine. I'm a little baffled because Les and a couple emails to Malone trough 2 weeks and I have been trying to clear it by the method stated earlier. Kinda shocked they didn't suggest that. Not a cheap shot at them at all because they are the guru's. Maybe we have different issues going on??
 

Coffeemade

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you have a different issue than me. I think something isn't right about your install, like where is the adblue injector?

I did start the car after I was flashed back to a tune with the DPF, then waited 1 minute and started it and then pulled the ECU and flashed it back to DPF delete tune.

I never had any check engine lights only DEF/Adblue warning that wouldn't clear.
 

767wrench

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Thought I was in the clear with my install! so far so good at 19k miles. Hope mine holds out!
 

dogger37

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767 wrench who did your install? And after 19,000 would you do it again?
 

aullein

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ok guys going to take pix today when its on the lift at the shop. Will post if it might help me out. anything I should be looking for?? All holes in the downpipe should be filled with a sensor or injector and nothing left unplugged correct??
 

767wrench

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My exhaust flap is disconnected. thats the only one. and my egr is blocked off.
 

LokiWolf

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ok guys going to take pix today when its on the lift at the shop. Will post if it might help me out. anything I should be looking for?? All holes in the downpipe should be filled with a sensor or injector and nothing left unplugged correct??
Correct.
 

VeeDubTDI

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I don't think you'll find unfilled holes in the downpipe, as that would create a major exhaust leak. What you should be looking for is homeless sensors and unplugged connectors.
 

767wrench

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Just an interesting thing I found yesterday. So as the first Passat dpf delete car, my delete still injected DEF fluid at a low rate like in cold weather operation. I filled my DEF at the time of the delete to verify we had set the computer to a fixed value for DEF in tank. After 19k miles I filled it last night and it took 4.75 gallons. no warnings or anything so far! i just updated to the newest tume which supposedly doesn't inject DEF so well see what happens over time
 

aullein

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So I go and check my exhaust pipe in the garage and guess what's in the end of it??

Tada!!!! The DEF injector ... Unbelievable all I can do is laugh
 

aullein

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They DEF injector was never taken off the original exhaust and mounted onto downpipe. They left it on there and didn't reinstall it.
 

VeeDubTDI

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Aha! I understand now. That might have something to do with it. ;)
 

MichaelB

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I have been following this thread since it's inception. All this bother and frustration, all this lost time, all the money's spent just to have a dpf delete tune. Learning curve I guess. Still best of luck. Hope it all works out in the end
 

767wrench

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Id rather deal with the Dpf permanently on my own terms and time of my choosing rather than get hit with another turbo failure or dpf related issue out of warranty on a Saturday night at midnight in 10 degree temps a couple hundred miles from home and then be forced to go to the dealer and spend 5k to buy a new turbo, intercooler, dpf, and all related sensors and labor
 

Lightflyer1

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Maybe, but you are assuming you will have an issue and so far few have. Maybe you should put a new engine in every 10k miles so there is no issue there either. I keep a $1k car around for those instances. Then I can make decisions at my leisure. Insurance is only $100 a year or so for liability as a third car with 2 drivers (pleasure vehicle). Comes in handy when guests visit as well as I don't have to let them drive mine.
 

aullein

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Yes but we ran into another problem. Hopefully not a big one though. The electrical connector to the DEF injector coming from the wirige harness won't reach the injector in the downpipe !!! It's about a half inch short. We gently pulled with the car on the lift but doesn't feel like there is any slack. Would it be ok to cut and splice those wires??

Now I am assuming the bung where the injector is in, is where the injector is supposed to go. The earlier kits you had to cut and weld the bung in from the original exhaust onto the downpipe in order to make work. Im pretty sure it's in the right spot.
 

VeeDubTDI

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It doesn't really go in the down pipe... more like the mid pipe under the middle of the car. That's probably why the wires don't reach.
 

aullein

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Ok yes more like the midpipe my bad for use of words. After the hangars before the resonator is where it's at. Any reason why I can't cut and splice?? Butt connectors best or should I go something different ? Only need no more than an inch maybe 2 at most for a little slack if needed.
 
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