A DPF (Diesel Particulate Filter) also known as FAP on some French vehicles, is a device fitted to the exhaust system of modern diesel vehicles to reduce emissions and meet European emission standards.
WHAT IS A DPF?
A DPF (Diesel Particulate Filter) also known as FAP on some French vehicles, is a device fitted to the exhaust system of modern diesel vehicles to reduce emissions and meet European emission standards. It does this by trapping Soot (Particulate Matter - PM) from the exhaust gasses while letting the gasses flow through the system.
As with any type of filter a Particulate Filter needs to be cleaned regularly to function properly. With DPF’s this is done by a process known as Regeneration which involves a combination of a Catalyst function in the system and burning the soot to gas at a very high temperature leaving behind an Ash residue within the DPF. Regeneration should be an automatic process taking place in the normal use of your vehicle, you may have noticed this in the form of a blast of white smoke form the exhaust on occasions.
DPFs have been in common use in passenger cars and light commercials from around 2003 in preparation for Euro 4 regs (2005), with Peugeot, Renault and BMW being early takers. Euro 5 (2009) made it compulsory for diesel cars and light commercials to have a DPF fitted and Euro 6 2014 will tighten this up further.
PROBLEMS ENCOUNTERED WITH DPF
If regeneration doesn’t function properly it leads to a build up of soot affecting performance and fuel economy, left unattended this will result in a Blocked DPF which can ultimately cause very expensive damage to other engine components. A blocked DPF is also potentially dangerous as it can cause overheating in the exhaust system and cause a fire risk. To prevent this damage most newer vehicles will go into “Limp Home” safety mode at this stage, meaning the vehicle will have minimum power barely sufficient to crawl home. For regeneration to take place it requires the vehicle to be driven regularly at some speed on open roads e.g. motorway driving, typically driving at around 2500 RPM for approx 30mins at least once a month, this will keep things working. However, many diesel vehicles are used primarily in urban areas or on short stop start journeys e.g. local deliveries, taxi’s, school runs etc and many have auto gearbox, so the vehicle does not get the chance to heat up sufficiently and is unable to carry out a full regeneration process.
Even if the regeneration functions as it should, over time the Ash Residue will build up in the DPF and have the same affect ultimately resulting in a blocked DPF. For this reason a DPF is classified as a Serviceable Item by the vehicle manufacturers like brake pads or air filters etc and not covered under warranty. DPF systems therefore need to be maintained properly.
WHAT ARE MY OPTIONS?
If your DPF warning light or Anti-Pollution warning is on, please do not ignore it (typical dash warning symbols below). Get professional advice, consider your options carefully and attend to the problem. Leaving it will ultimately cost you much more in additional repair bills and it can be dangerous.
By the time your DPF warning lights are visible your DPF will already be significantly blocked. Forced regeneration by a garage or a “blast down the motorway” is not likely to cure the problem, these only work as preventative maintenance. So at this stage realistically you have the following 3 options:-
DPF Replacement – Quantum dealers can replace the DPF at a fraction of the main dealer cost. They carry out full diagnostic checks, replace the DPF unit, recalibrate the ECU, reset the warning lights and run a road test. They can also add a bespoke remap at the same time to improve fuel economy and performance, ask about our special discount package.
The ideal DPF solution for you depends on your circumstances e.g. type & condition of your vehicle, your usage, your future plans i.e. whether you intend to keep or sell the vehicle etc and your budget.
WHAT ELSE SHOULD I BE AWARE OF?
It is often said that you should “go for a blast” down the motorway to clear the DPF. Please note this is only partially true. If the DPF is blocked beyond the capacity for regeneration or blocked due to Ash residue, you will do more harm to your engine.
There are many DPF cleaning additives available promising a magic cure for DPF. We have yet to find one that will clear a blocked filter and will certainly not clear an Ash blocked filter. Some products can however be useful in keeping a functional DPF in good health.
DPF units are closely linked with other emissions components, if these parts do not function properly they can help to block the DPF, similarly a blocked DPF can damage these components due to excess back pressure.
DPF units are located close to the Turbo, if the turbo is leaking oil it can help to block the DPF, similarly a blocked DPF can damage the turbo due to excess back pressure.
Some PSA engines fitted to Peugeot, Renault, Ford, Volvo and Nissan have an on board Fuel Additive System connected to the DPF to help regeneration. It is importantto maintain this system and keep it topped up with the additive (only available from main dealers approx £130 per tank) if not it will block the DPF. In our experience this is often neglected, even by main dealers due to the cost.
Some vehicles have a dedicated DPF or Emissions or Anti-Pollution warning light which is great, however many will just have an Engine light on. It is important to check by diagnostics why the light is on and not advisable to simply get the light turned off without investigation.
DPF work is complex and should only be carried out by experienced professionals with the correct specialist equipment. All work on a DPF has to be completed with the appropriate recalibration or reset on the vehicle ECU. It is not possible to simply delete the DPF electronically or just remove the DPF unit without work on the ECU.
It is our experience that many garages including main dealers are not knowledgeable in DPF and related issues. Our dealers often see customers after they have spent a lot of money on the wrong fixes as the DPF fault was not correctly diagnosed. Diesel Particulate Filters were designed with good intent to reduce emissions and offer a better environment. In theory a DPF would trap soot in urban areas and then regenerate on the open road, unfortunately this does not always work well leading to expensive repairs. The fact that DPF units are made with expensive minerals like Platinum, that excess fuel is needed for the regeneration process and that ultimately the accumulated soot and ash has to go somewhere… back into the environment which many now question the overall environmental value of the entire life cycle.
IS DPF REMOVAL LEGAL?
It is not illegal to remove the DPF, however in the UK it is an offence to use a vehicle on the road that no longer complies with the emissions standards it was designed to meet.
Changing any part of the exhaust or emissions system with a part other than the vehicle manufacturer’s original part that may change the emissions could be an offence. Currently emissions testing outside the London Emissions Zone (LEZ) is limited to the standard MOT test.
From February 2014 the inspection of the exhaust system carried out during the MOT will include a visual check for the presence of a DPF canister, if fitted as standard equipment.
QUANTUM TUNING DPF SERVICE
It is the consumer’s decision if they wish to have the DPF Solution.
Furthermore, the MOT testing criteria is constantly changing so there is potential in future that you may be required to install a new filter? If this is the case your Quantum dealer can remove the DPF deletion software.
A widely adopted route to reduce NOx emissions is Exhaust Gas Recirculation (EGR). This involves recirculating a controllable proportion of the engine's exhaust back into the intake air.
EGR SOLUTION, EGR SOLUTION | EGR SERVICE, EGR - EXHAUST GAS RECIRCULATION
WHAT IS EGR?
A widely adopted route to reduce NOx emissions is Exhaust Gas Recirculation (EGR). This involves recirculating a controllable proportion of the engine's exhaust back into the intake air. A valve is usually used to control the flow of gas, and the valve may be closed completely if required.
EGR SOLUTION | EGR SERVICE
Here at Quantum we have a very advanced solution for EGR removal. The valves can become clogged with carbon deposits, causing them to fail or stick, thereby causing error codes and the vehicle not to run correctly. Our software solution to disable the EGR valve is a simple and effective method of improving the efficiency of your engine.
WHAT ARE THE BENEFITS?
Modern engines recirculate some of their exhaust gases back into the engine with the aim of reducing emissions. This is the is the main benefit of the EGR system. The downside is that exhaust fumes containing carbon deposits are constantly being recirculated through the engine through time causing a build-up of carbon deposits in the intake manifold etc.
These deposits sometimes contribute to the failure of the EGR system itself. Replacement EGR valves can be expensive and in the case of high mileage engines the continual carbon build up can eventually lead to total engine failure.
Removal of the EGR system by banking off the exhaust input and reprogramming of the engine management ECU results in lowered engine temperatures, improved throttle response and economy and also can lengthen engine life by reducing oil contamination and carbon deposits.
HOW EGR WORKS?
The EGR theory works by sending a small part of inactive gas exhaust back into a vehicle's cylinders, hence eject negligible toxins into the environment. This reduces the heat of combustion yet the same amount of pressure is still applied to this piston while reducing the amount of excess oxygen prior to combustion. A few studies conducted on diesel engines demonstrate that the portion of nitrous oxide gas emissions is definitely reduced through the use of EGR, however concentrations of smoke density can actually increase. Thus there seem to be pluses and minuses depending on what's important to you in your specific vehicle
Usually, an engine recirculates exhaust gas by piping it from the exhaust manifold to the inlet manifold. This design is called external EGR. A control valve (EGR Valve) within the circuit regulates and times the gas flow. Some engines incorporate a camshaft with relatively large overlap during which both the intake valve and the exhaust valve are open, thus trapping exhaust gas within the cylinder by not fully expelling it during the exhaust stroke.
IS IT LEGAL?
At present it is not illegal to remove the EGR valve and it doesn’t form part of the MOT test. Whether this might be tightened up in the future, no one knows and our best guess that even if it is, then it will not be applied retrospectively.
Since the EGR system recirculates a portion of exhaust gases, over time the valve can become clogged with carbon deposits that prevent it from operating properly. Clogged EGR valves can sometimes be cleaned, but replacement is often necessary if the valve is faulty.
All modern cars and vans on the road today have an ECU (ENGINE CONTROL UNIT). This Engine Control Unit can almost be described as the vehicles ‘brain’ and...
... contains a processor that takes information from various sensors throughout the engine. It analyses information such as the engine temperature, accelerator pedal angle, oxygen content in the burnt exhaust gases as well as many more parameters. Using the information from these sensors it can then add the right quantity of fuel, at just the right time to provide a good mix of fuel economy, performance and emission control when pulling away, overtaking, pottering down the road or zooming down the motorway.
WHAT IS ECU REMAPPING?
When a manufacturer develops a new car they have to take into consideration all of the conditions it may be subjected to in all of the regions in which they intend to sell this model. This means instead of just optimising the ECU’s program or ‘map’ to deliver the best performance or the most fuel efficiency they have to make compromises to the map to take into account these potential differing operating conditions. These could include sub-standard fuels, extremes in temperature and altitude, differing emission laws and even the possibility that vehicle may not be serviced on a regular basis and in accordance with the manufacturers recommended instructions.
ECU remapping is taking a read from the ECU’s processing chip of the vehicles standard compromised map and adjusting various parameters within the map such as fuel pressure, boost pressure (on turbocharged applications) ignition advance and throttle pedal control amongst others to release the true performance from the engine. It is a completely safe process as it is just giving the engine the performance it should have had in the first place before all the compromises were applied to the original programming. Every engine will have its own unique map and by adjusting this we can fine tune the characteristics of the engine; unleashing more power and in many cases reduce fuel consumption too.
BENEFITS OF ECU REMAPPING.
ECU remapping will not only improve the engines power and torque figures, it will also sharpen the throttle response and widen the power-band. This will make the power delivery a lot more linear, which in turn will make the vehicle feel a lot livelier to drive and the engine more flexible. Frequently, the vehicles power output is restricted by the manufacturer for no other reason than to ensure that the vehicle fits into a class to suit fleet buyers. As a driving enthusiast, you do not need or want such restrictions placed upon your vehicles ECU and its performance therefore you can benefit from the hidden power and torque locked away within your engine management system.
The other main benefit of remapping will be a reduction in fuel consumption. With the extra torque especially at the bottom of the rev range you will see a fuel saving, as it will require less throttle input to maintain motorway speeds, you can drive in a higher gear at a slower speed as well as helping significantly when fully laden, towing or on gradients and even in start stop traffic.
Turbocharged Diesel Engines
ECU REMAPPING BENEFITS FOR TURBOCHARGED DIESEL ENGINES
Many see the modern crop of Turbocharged diesels as the future of road car tuning. These engines offer fantastic potential for reliable low cost tuning without removing any of the appeal of buying and running a turbo diesel powered vehicle, such as economy, reliability and longevity.
After your ECU upgrade to your turbocharged diesel engine, you will enjoy:
- Increased horsepower
- Increased torque
- Better throttle response
- Smoother power delivery
- Improved fuel economy
- Safer overtaking
ECU REMAPPING BENEFITS FOR TURBOCHARGED PETROL ENGINES
Turbocharged petrol engines have always been regarded as the sports flagship engine for good reason. They boast far higher power & torque figures than a non-turbocharged power-plant with similar displacement and are usually fitted to the manufacturer's flagship models. They are also ideal candidates for remapping as the ECU also controls the wastegate (turbo boost pressure control).
After your ECU upgrade to your turbocharged petrol engine, you will enjoy:
- Increased horsepower
- Increased torque
- Better throttle response
- Smoother power delivery
- Safer overtaking
- Improvements in fuel consumption on petrol engine vehicles are smaller and nothing like that achieved by diesel vehicles.
ECU REMAPPING BENEFITS FOR NON-TURBOCHARGED PETROL ENGINES
The normally aspirated petrol engine, whilst not being the easiest of engines to tune, can still benefit from a 8-15% power increase with added torque by careful reprogramming of various engine parameters within the map. Parameters such as the fuel and ignition curves can be fine-tuned to give better power & torque output. On some engines the camshaft timing can also be tuned within the map, giving additional improvements.
In many cases, 'after market' tuning items such as freer flowing exhausts, high flow air filters and re-profiled camshafts can only be fully utilised by the engine once the necessary adjustments have been made within the ECU. Careful recalibration of the correct maps can unlock the potential of your new engine parts. Further power gains may also be available when a higher octane fuel is used, allowing for more ignition timing.
SAVING FUEL WITH ECU REMAP?
When we remap a vehicle, especially when fuel saving is the priority we focus on improving the low end torque in particular and widening the power-band as far as we can.
This increase in low end torque will mean less throttle pedal input is required to maintain cruising speeds, when fully laden or when on a gradient. It will also mean that the vehicle will be more comfortable in higher gears at slower speeds as well requiring fewer gear changes overall.
If you combine these factors with adjusting your driving style to make the most of the extra low end torque you will see an improvement in fuel consumption. This is most effective on turbo-diesel engines where the savings could be as much as 20%!
WHAT DO YOU ACTUALLY MODIFY IN MY VEHICLE?
We do not change any hardware in your vehicle, we just modify the operating parameters in the ECU’s program or ‘map’. In many cases the map stored on the ECU’s processor can be accessed via the on-board diagnostics port (OBD) in the vehicle, normally found under the dashboard. In some newer models the ECU will have to be removed from the vehicle and the casing opened, our technicians will then use specialist tools to read the original map straight from the processing chip.
The technician will then upload the original map to our map writing team who will adjust the parameters to maximise the performance, fuel economy or a clever blend of both. Depending on the vehicle and ECU type the remapping process can take under an hour and if at any time you wish to return your vehicles ECU to its original default settings, this can be done easily and free of charge as we always keep a copy of the original software as a backup.
IS ECU REMAP LEGAL?
YES - There is nothing illegal about remapping an ECU on an engine. Although you should inform your insurance company of any alterations made to the vehicle.