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VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives

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  • #1 16793487
    Radow
    Level 13  
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    The patient is the engine 1.6TDI design with 2009 on CR .

    The car initially started the emergency mode because the throttle jammed + it did not burn out with dpf = the entry in the emergency trim (beads + dpf control).

    After replacing the throttle, visiting several "tuners" everyone stated that dpf is not yet to be replaced / cut because its consumption is estimated at 1/4 1/3.

    The problem is that while driving the car fills up dpf all the time until the filter panel appears on the top of the car - just go to the gas station and wait for a moment and the car burns back to 900.

    You can also notice that before the control is displayed and it already has a fill, it burns at every stop.


    The problem appears on the route - namely at longer sections when the indicator light is on, you can go 50, 100, 200km and you can I will not smoke (so much from driving off the car on the highway) but just pull off for a moment on the shoulder and the procedure is active and burns out. In such a situation the car surprisingly prefers a city like a highway because there is more = there is time for burning. Needless to say, the car stalls a lot because it enters the firing mode and there are other consequences of a badly functioning system. Can you check somewhere in the VCDS if the procedure is not turned off while driving?

    It behaves in a nutshell as if you were switching off the cleaning procedure of the filter while driving, and only when it was stopped it switched on.

    I will add that it has a VCDS diagnostic tool, changed the dampers (so that it does not blow beads), and a dpf pressure difference sensor.
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  • #2 16793629
    Ireneo
    Level 42  
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    Hmmm ...
    Filling, injections ....
    Fairy I'm not
    Other parameters.
  • #3 16793645
    Radow
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    Injection one of the tuners checked and does not "fly" but if you have any other test (specific parameters) then please write how I choose it and read it.
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  • #4 16794114
    Ireneo
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    What did this tuner still check?
  • #5 16794133
    szymitsu21
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    Start by measuring the differential pressure.
    3 gear and full load, the other thing was there any modification for you?
    Power, egr?
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  • #6 16794217
    Radow
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    he has checked the turbo that is ok

    He still said that it can be from the throttle - (the truth is sometimes stuck but not always). after exchange, however, the same.

    Auto from DSG7. No chips, egr not blinded
  • #7 16800035
    Radow
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    Is it possible to "reset" the dpf setting to factory settings?
    is there any tab in vcds responsible for dpf and firing on the route? Maybe after KM?
  • #8 16800054
    szymitsu21
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    Radow wrote:
    Is it possible to "reset" the dpf setting to factory settings?
    is there any tab in vcds responsible for dpf and firing on the route? Maybe after KM?


    you can make a change. so ECU will think that new (for a moment).
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  • #9 16810514
    Radow
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    Up. How to do it in VCDS? Reset the indications? but will not it be cheating all the time that I have a place and will not be at all?

    -----------------------------------

    No other ideas suggestion? (possible measurements)
    Is it removed and deleted from the dpf-a program that should technically be functional?
  • #10 16817064
    boch
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    Hard topic. In our country, the causes of DPF problems are not repaired. It just cuts them out. I would say it in bulk. Two years ago, you would have waved your hand and the filter got rid of it. Today when the tug of war on turbodysels is getting bigger so it makes sense for as long as healthy DPF to fight. I would focus on the throttle start. However, it can be cut or loose, which causes problems with the initiation of the firing process while driving. From what I read (I do not know if all cars with DPF), the firing process starts with stopping the damper to a value of around 20% (firing optimization). EGR is also closed (completely). Maybe recharging while driving disrupts the appropriate angular position of the throttle flap and thus prevents starting firing. At the stop, the recharging is smaller, the flap adopts the appropriate angular position and the regeneration process begins. It's so for my peasant reason, that's why someone with DPF and VAG would be useful.
  • #11 16817480
    szymitsu21
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    A friend on rossstech you will find everything.

    Just type in the search engine and all the procedures you have on the table.

    What is the differential pressure after all?
  • #12 16853368
    Radow
    Level 13  
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    I managed another diagnostic program to start this problem because sometimes they write with vcds too weak and by the way I had to "fail" to burn the DPF (it's no wonder if it does not burn while driving). Of course, after burning check and dpf disappeared.

    So one by one (I did not know what could help you, so there is a lot)

    1. VCDS only preliminary measurements:
    VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drivesvcds2.jpg (4.16 MB)You must be logged in to download this attachment. VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended DrivesVCDS.jpg (293.53 kB)You must be logged in to download this attachment.

    2. Pomiary Delphi

    a) przed wypaleniem awaryjnym dpf na postoju:
    VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives1.jpg (150.72 kB)You must be logged in to download this attachment. VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives1 (1).jpg (113.37 kB)You must be logged in to download this attachment. VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives1 (2).jpg (2.34 MB)You must be logged in to download this attachment. VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives1 (3).jpg (194.92 kB)You must be logged in to download this attachment. VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives1 (4).jpg (160.66 kB)You must be logged in to download this attachment.
    b) after firing dpf at a stop (all possible measurements)
    VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives



    2.ab (transition phase during firing start and end)
    VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drives


    I am curious about the adaptation of the exhaust gas sensor: (I did not)
    VAG 1.6TDI 2009: DPF Filling and Burning Issues During Extended Drivesadaptacja ...ujnika.jpg (131.93 kB)You must be logged in to download this attachment.

    I will add that this is my last attempt to take up the subject - I will probably be forced to capitulate and do what others get rid of "just like a broken tooth" because I have enough money for tuners who can do what I do at home (eg burn dpf at a standstill) too thick $$$ ...). Damaged dpf-damages the rest of the car and can not be any more.
  • #13 16853470
    Ireneo
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    Probably that capitulation. I have seen these foty and I see that you do not know what to look at. I looked because I thought I could not see but I see other groups before and after.
  • #14 16853514
    Radow
    Level 13  
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    Well, I do not know what I'm looking at ... Ba ... But the local tenants do not know either ;) .

    In the pictures after firing are all available readings available in the "engine".
    If you tell me what to look at, then this is a detail of the screenshots.

Topic summary

✨ The discussion revolves around issues with the DPF (Diesel Particulate Filter) in a 2009 VAG 1.6TDI engine, particularly during extended drives. The car experiences frequent DPF filling, leading to emergency mode activation due to throttle jamming and inadequate regeneration. Various tuners have assessed the vehicle, indicating that the DPF does not need replacement yet, but the throttle may be contributing to the problem. Suggestions include measuring differential pressure, checking for modifications, and potentially resetting DPF settings using VCDS. The conversation highlights the complexity of DPF issues, with some users advocating for DPF removal as a last resort, while others emphasize the importance of maintaining a functional DPF.
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FAQ

TL;DR: On VAG 1.6 TDI (2009, CR), regeneration typically commands the throttle to about 20% and closes EGR; as one expert notes, “the firing process starts… around 20%.” [Elektroda, boch, post #16817064]

Why it matters: This FAQ helps 1.6 TDI owners diagnose DPFs that fill on highway drives but only regenerate after stopping, using VCDS-friendly checks.

Quick Facts

Why does my 1.6 TDI only regenerate after I pull over?

The ECU targets a specific throttle angle (≈20%) and closes EGR to start regen. If the throttle flap sticks or commanded angle isn’t achieved during cruising, regen defers. When you stop, load and airflow change, the flap hits target and regeneration begins. Check throttle operation and commands during suspected regen windows. “The firing process starts… around 20%.” [Elektroda, boch, post #16817064]

Which VCDS measuring blocks or procedures should I use to confirm regen is enabled while driving?

Use Ross-Tech documented procedures in VCDS to monitor DPF soot load (calculated/measured), regeneration status, and enable criteria. Verify differential pressure, exhaust temps, and throttle/EGR commands. If any preconditions fail, the ECU delays regen. Follow the step-by-step guidance on the Ross-Tech knowledge base referenced in the thread. [Elektroda, szymitsu21, post #16817480]

How do I measure DPF differential pressure correctly on this engine?

Log differential pressure in 3rd gear at full load to see backpressure under flow. Compare idle vs load values and note spikes that suggest blockage or sensor/hose issues. A member advises, “Start by measuring the differential pressure.” Use manual mode on autos to hold 3rd. [Elektroda, szymitsu21, post #16794133]

Can I reset the DPF adaptation so the ECU ‘thinks’ the filter is new?

Yes. You can change the adaptation so the ECU treats the DPF as new. This is a diagnostic aid, not a repair. Use it to validate sensors and regeneration logic after fixing root causes. Don’t run long-term with an inaccurate soot model. [Elektroda, szymitsu21, post #16800054]

What components most often block regeneration on this case?

Focus on the throttle body and EGR control. Regen needs a specific throttle angle and closed EGR. A sticky throttle or incorrect actuator response can prevent initiation at speed. Inspect for binding, contamination, and learn values after replacement. Verify commanded vs actual angles in logs. [Elektroda, boch, post #16817064]

Does a forced stationary regeneration fix the issue?

It clears soot temporarily, but the highway problem returns if the underlying control or sensing fault remains. The thread author performed a forced burn; warnings cleared, then the pattern recurred. Use forced regen only after verifying hardware and sensors. [Elektroda, Radow, post #16853368]

Could injector problems cause constant DPF filling?

Yes, poor injection control increases soot and delays regen conditions. The thread flags injections as a parameter to verify. Check correction values, leak-back, and commanded vs actual fueling under load before chasing the DPF alone. [Elektroda, Ireneo, post #16793629]

What is a DPF and how does this engine trigger regeneration?

A diesel particulate filter traps soot and periodically burns it off. On this platform, regen starts when the ECU commands about 20% throttle and closes EGR; the right temperatures and pressures must also be present. Throttle or EGR faults can block the start. [Elektroda, boch, post #16817064]

How can I road-test to catch the fault quickly?

  1. In 3rd gear, full load, log DPF differential pressure, throttle angle, EGR command, and regen status.
  2. Maintain steady cruise, then pull over briefly and watch for regen start.
  3. Compare commanded vs actual throttle; mismatches point to throttle/EGR issues. [Elektroda, szymitsu21, post #16794133]

My car can drive 50–200 km on the highway without regenerating. Is that normal?

No. In the case reported, regen would not start for 50–200 km of highway driving but began shortly after stopping. That pattern indicates a control precondition not met at speed, often throttle angle or sensed backpressure. [Elektroda, Radow, post #16793487]

I have DSG7—anything special when testing?

Yes. Select manual mode to hold 3rd gear during full-load logging for stable differential pressure data. Without manual hold, the transmission may upshift and skew readings. The case vehicle used DSG7 with this approach. [Elektroda, Radow, post #16794217]

Is removing the DPF a sensible solution here?

The thread notes DPF removal is common locally, but it avoids fixing the cause. With diesel scrutiny rising, keeping a healthy, functioning DPF protects the engine and compliance. Diagnose throttle/EGR and sensors first. [Elektroda, boch, post #16817064]

We replaced the differential-pressure sensor. Could it still be the issue?

Yes. Replacement alone doesn’t rule out problems. Verify the hoses for blockage or leaks and confirm the new sensor reads plausibly at idle and load. In the case, the sensor was changed but symptoms persisted, implying remaining faults upstream. [Elektroda, Radow, post #16793487]
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