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Reliable DPFs and EGRs - HandCart

1) Is there a car manufacturer that has built up a deserved reputation for engineering a DPF system that simply works properly and is never a concern?

2) Same question regards EGR valves (on diesel engines)

3) Is it true that even if a car has a DPF system that satisfies Question 1, the DPF will inevitably eventually fill up with ash anyway, and will therefore need to be removed and cleaned or replaced?
If so, how much does a remove+clean+replace cost?


I do about 24k miles a year, about 1/3 of which are long runs (360 mile round trip), and the rest local journeys, though most of these are more like 3 to 10 miles rather than say 1 mile or less.

Reliable DPFs and EGRs - Gibbo_Wirral

I know a few Peugeot 407 owners with both in their cars and they're not a concern because the cars are used on motorways or dual carriageways a great deal.

The problems start when people just use diesels for pootling round town. No system will be able to work in those conditions for very long.

Like exhausts and cats, DPFs also have a lifespan. Again, it depends on car usage, but around 120,000 miles life is common, but I've seen them get blocked at 50,000 on the town pootlers.

You can get them cleaned from about £50 (Halfords offer a service and say it should be done every six months).

For a cheap DPF, cats2u are pretty reasonable, but prices depend on car.

Reliable DPFs and EGRs - Engineer Andy

Maybe worth considering buying an efficient petrol engined car and hiring a diesel car for the longer trips, or getting a hybrid petrol. You'd need to crunch the numbers for the whole life cost of ownership, including factoring in DPF/EGR cleaning (type of mileage dependent) and even replacement of such items for diesel cars.

For those people in two-car (plus) families, where one is already a diesel (and is properly used for longer journeys only) and the other petrol (for the mainly shorter journeys), it may be worth in such cases swapping them over when the long trip comes along, to make the best use of the diesel's efficiency and to clear as much out of the DPF as is possible via passive regens during the trip. This may not be applicable in this case or for most people.

If its for work purposes, I'd ask my boss if they'd consider hiring a car for those longer trips as it may be cheaper for them and paying just for the rental plus fuel, rather than you Xp per mile for use of your car, or huge depreciation (or high lease charges) for a car with 72k after 3 years of ownership for a new company car.

Seems from a reasonable amount of feedback that the latest Honda diesels are the most resilient to DPFs clogging up in short order, but that doesn't mean they won't, just not so quickly.

Reliable DPFs and EGRs - skidpan

Simple fact is regardless of how reliable the system is every time a regen takes place the particles are converted into ash. Once the ash is there its there for life. That is why DPF diesels use engine oil that is classed as low ash.

Some claim the ash can be removed by either cutting the DPF open or using a company that has a snake oil that will dissolve it, neither is garanteed.

The only 100% way to sort is a new DPF.

Even in motorway use the DPF will probably ash up in about 100,000 miles.

Since you can get diesel like economy and driving characteristics from a modern small turbo petrol I will not be buying a diesel again.

Reliable DPFs and EGRs - madf

The hassle low miles mean to a EGR diesel car make it a PIA at MOT time. Lots of diesel treatment stuff and a 30 mile Italian tune up to pass MOT.. And that's with no DPF.

Spawn of the devil stuff

Reliable DPFs and EGRs - Steveieb
One alternative which I use is to find a diesel without anything beyond Euro 4. This means finding an older vehicle.
I have heard that some van operators are choosing older vehicles with no Dpfs and spending some money on repairs and TLC
Reliable DPFs and EGRs - badbusdriver
One alternative which I use is to find a diesel without anything beyond Euro 4. This means finding an older vehicle. I have heard that some van operators are choosing older vehicles with no Dpfs and spending some money on repairs and TLC

Thats OK if you live out in the sticks and have no need to go into a city centre, but the way things are looking, such vehicles will be banned from city centres in the not too distant future.

I'm not sure, but i don't think my 2010 Caddy 2.0 SDI (non turbo) has a particulate filter, and no idea what 'euro' number it is, but the closest i get to a city centre is the very outskirts of Aberdeen, so i very much doubt it will affect me. Though as far as i am aware, Aberdeen has made no mutterings about an exclusion zone for older 'dirty' diesels.

Reliable DPFs and EGRs - SLO76
“I'm not sure, but i don't think my 2010 Caddy 2.0 SDI (non turbo) has a particulate filter, and no idea what 'euro' number it is, but the closest i get to a city centre is the very outskirts of Aberdeen, so i very much doubt it will affect me. Though as far as i am aware, Aberdeen has made no mutterings about an exclusion zone for older 'dirty' diesels.”

Sure doesn’t, thus the reason why I bought one myself and had many reliable miles from my wee Caddy. Bound to fall foul of environmental legislation at some point in larger cities like Edinburgh and Glasgow but I doubt there will be any need elsewhere in Scotland. We’ve enough fresh air to go around.

Edited by SLO76 on 16/01/2019 at 20:25

Reliable DPFs and EGRs - 72 dudes

I have a Euro 4 diesel without a DPF and it's been faultless. It's a 2007 Mercedes A180 CDi CVT auto. My small business means I do lots of short journeys around town, with the occasional longer journey and Italian tune-ups. I've had it for almost 5 years, so that's probably a reasonable length of time.

Previous diesel cars I have owned privately include a Volvo S40 2.0D (no DPF but the EGR eventually played up ) and a 2001 Citroen C5 2.2 HDi which had a DPF with Eolys and EGR and I had numerous problems which all garages I tried failed to fix, leading to it's departure.

As I understand it from Merc forums, MBs seem to suffer less form the usual diesel problems.

Reliable DPFs and EGRs - HandCart

Thanks 72Dudes, that's interesting information.

Has your Merc been faultless in other regards too?
It seems pretty surprising, given that neither CVTs, nor the tall A-class, seem to have sterling reputations in general..

Reliable DPFs and EGRs - 72 dudes

No, not faultless. The most expensive issues I had were (a) alternator pulley and bearing failure about 3 years ago, around £350, and (b) yesterday new rear brake pipes as part of a big service, which meant an extra 3 hours labour.

Otherwise it's been regular servicing and tyres and a flat battery two years ago.. Luckily I use a Merc specialist in Stowmarket who keeps costs well below that of a main dealer.

The A Class (2005 to 2012) has a poor reputation but I think it's mainly down to the first version (1999 - 2004) which was not a good car at all.

Avant had a B Class and hated it, so it's horses for courses.

The CVT gives little trouble actually, I've come across very few issues on the forums, and in combination with the diesel's torque, make it very relaxing and efficient to drive. It's old school rumbly though.

MPG over last 4.75 years has been 44.3 brim to brim, which I think is good for an older 2.0 diesel with CVT which does a lot of short journeys.

Edited by 72 dudes on 16/01/2019 at 21:26

Reliable DPFs and EGRs - HandCart

Yup, for an older 2.0 diesel with CVT which does a lot of short journeys, 44.3 mpg does seem pretty good :-)

Reliable DPFs and EGRs - Avant

"Avant had a B Class and hated it, so it's horses for courses."

Well remembered, given that it was over 10 years ago! In fairness, I didn't hate it because it was unreliable. It was a combination of lifeless steering, stodgy handling and above all the loud, constant drone from the combination of 4 cylinders, diesel and CVT. Plus windscreen wipers which, despite being 'clap-hands', were set up to favour LHD.

I've always been rude about Mercedes as German taxis: this was my come-uppance as a London taxi is exactly what my B200 CDI sounded like.

Edited by Avant on 17/01/2019 at 00:33

Reliable DPFs and EGRs - craig-pd130

The 2.0 TDCi motor in the Mondeo IV / SMax / Galaxy etc had a very robust DPF & EGR system - I had a Mondeo for over 3 years from 2008 to 2011 and it was faultless. Very few complaints on the Ford forums about DPF or EGR problems in those.

They seemed to have got the implementation pretty much right first time. I don't know if the more recent Mondeos have maintained the same standard as we've moved to Euro V etc.

Reliable DPFs and EGRs - sandy56

My last car I ran for 4 years a Peugeot 407 2l hdi ( very useful estate) diesel had no problems with the DPF/EGR. My current car Honda CRV 2.2l diesel I have had for two years and no problems with DPF/EGR.

I do have them regularly maintained, and use super diesel, and they get motorway runs on occasion.

Some emission systems don't seem to be reliable, so do your research before buying any car.

Reliable DPFs and EGRs - HandCart

Interesting about the Mondeo and 407 2-litre diesels. For myself, I think I would be looking for a smaller engine, to help with the economy on the 'more local' trips. However the Ford/PSA 1.6 is notorious for problems with the turbo oil feed, and the 1.4 for problems with the injector seals, I believe.

I can't afford to buy something that is Euro 6, and what with these threats of ridiculous charges or bans on dirtier diesels from various cities, and non-plugin hybrids not being THAT economical on long motorway cruises, it looks like small-capacity petrol turbo will be the way to go (degas pipe notwithstanding - Oh! And the VAG 1.5 tsi, it seems) until 2040...

Edited by HandCart on 18/01/2019 at 22:37

Reliable DPFs and EGRs - Gibbo_Wirral

I think the problem with the 1.6 oil feed is down to wrong oil and Peugeot's initial recommendation of 20,000 miles between changes.

Reliable DPFs and EGRs - Graham567
I would second the Mondeo MK4 2.0 Diesel. I have had mine 9 years with all of it's life in stop start local traffic and never had a problem with the EGR or the DPF.
It does a regen every 500 miles so i take it for a good run when the car reaches this time.I also have always run it on Shell Optimax Diesel all it's life and used low ash oil using Magnatec oil.It's now done 56,000 miles and it's as good as the day i got it.

Edited by Graham567 on 21/01/2019 at 20:19

Reliable DPFs and EGRs - craig-pd130
I would second the Mondeo MK4 2.0 Diesel. I have had mine 9 years with all of it's life in stop start local traffic and never had a problem with the EGR or the DPF. It does a regen every 500 miles so i take it for a good run when the car reaches this time.I also have always run it on Shell Optimax Diesel all it's life and used low ash oil using Magnatec oil.It's now done 56,000 miles and it's as good as the day i got it.

You've reminded me of owning mine, my driving pattern was lots of urban stop/start with a 200+ mile trip every couple of weeks.

I worked out that the ECU would start an 'active' regeneration every 450 - 500 miles like clockwork, irrespective of how the car had been driven over the previous days. On a couple of occasions it started an active regen the day after I'd done 400+ fast miles at 80mph which was bang on the peak torque rpm of 2,250 (i.e. ideal conditions for 'passive' regeneration). I figured the ECU had a mileage-based regen routine programmed into it.

The active regenerations were easy to spot as the exhaust note became quite boomy and resonant, so like you I could simply drive for an extra 5 - 10 minutes until it finished.

Reliable DPFs and EGRs - badbusdriver

I think the problem with the 1.6 oil feed is down to wrong oil and Peugeot's initial recommendation of 20,000 miles between changes.

This echo's what i have heard. I was talking to someone i know who buys and sells cars and vans, and the PSA 1.6 came up in conversation. I said i would be reluctant to buy one due to this, he said that they were fine so long as, A, a reasonable service is adhered to, and, B, (in his words, this was critical) the correct oil was used. So while i'd still be a bit reluctant to buy used without a very detailed service history, i would be fine with buying one new.

Reliable DPFs and EGRs - SLO76
Loads of failures happen on this engine despite regular servicing. It’s a flawed design, especially early versions and is best avoided. I’ve seen them with ruined turbos at less than 60,000 miles and know plenty of traders and dealer buyers who won’t touch them beyond 3yrs of age. The 2.0 is a different beast and is based on the older 8v 2.0 HDi.
Reliable DPFs and EGRs - pd

For balance I'm poodling about in a car with the PSA 1.6 in it this week and it has......232130 miles on the clock. All original turbo etc. and probably DPF as well.

There is no such thing as a DPF which will last for ever in the same way there is no such thing as a tyre, brake, exhaust, engine, bearing, suspension bush, body control unit, bulb, ECU, blower fan, satnav reader, LCD display, seat spring, damper, or whatever which will last forever.

Everything wears out eventually and the car is scrapped.

The vast majority of DPFs do not cause a car to be scrapped. It is usually something else. Cleaning is usually about £100-£150 depending on the removal time. This usually keeps them going for a while.

They are something to bear in mind if your driving pattern is slightly unusual but most people never give them a second thought. For some reason this forum seems fixated on them at the expense of things which really do go wrong and cost a fortune.

Reliable DPFs and EGRs - Engineer Andy

I think the problem comes for people who drive essentially the opposite to you, but erroneously think that because they're driving a diesel that it must be more economical on ANY run that a petrol driven car.

People who drive low mileages with the vast majority made up of short urban trips from cold will see no mpg benefit over a modern petrol engine as they take far longer to warm up (and can be less fuel efficient when doing so), never mind the normal price premium in the car and the fuel.

They also convneiently forget to drive such cars sympathetically whilst they are warming up, hurting the components in the process and causing reliability problems to occur for earlier and far more frequently than if they didn't an/or, as you likely have done, mainly drove the car for longer distances per journey and did so sympathetically.

The DPF is no exception, and I remember people writing in to HJ and on these pages that they've had to have their DPF forcably regenned at the dealership once every couple of months, professionally cleaned out more than once a year and the component changed out (those cleaning methods don't work forever) only after 2 or 3 years.

This situation would be no different to someone owning a petrol engined car with a honking big turbo and ragging it all the time and shutting the car off before the turbo could cool down. The difference is that it's blindingly obvious to most people about not doing the latter; the former, not so much, mainly because so many have switched from a petrol car when such driving behaviour would be fine to a common-rail diesel with a DPF, where it certainly isn't.

Yes, the sales staff at dealerships have a reasonable degree of responsibility in not informing many such customers about this sort of thing, but to me, it's still the customer who is most to blame, especially from the late 2000s onwards when this problem in particular was well known, and could be found following a 5 minute search on the interweb. To me, such ignorance and laziness is no excuse.

Reliable DPFs and EGRs - pd

Obviously buy a car aimed at your needs. And a DPF equipped car may not meet them (or any diesel for that matter).

Nonetheless these days it is rarely a failed DPF, engine or gearbox (on manual cars, maybe clutch excepted) which sends cars to their grave. It is often electrical failures (doesn't mater how you drive them there), expensive suspension work needed for MOT, auto or automated gearbox failure or just a combination of brakes/tyres/service being needed on a car someone is bored with.

Most cars are carted off to the scrap yard with the engine running just fine, even diesels, no matter how they have been driven.

Reliable DPFs and EGRs - Engineer Andy

The thing is that if someone is driving a DPF-equipped diesel car unsympathetically and has to get a forced regen at the dealership every couple of months and a professional clean once or twice a year, that will more than outweigh (even with no replacement of the unti) any fuel saving and more over a similar sized petrol-engined car.

Costs like this can easily mount up, and they under stay 'under the radar' because they aren't the several £000s or more that a big, if rare issue over an engine or suspension crops up in one go. In such circumstances, I think many people would be put off buying a diesel if they were told (for low mileage/short trip users) that there was a reasonable likelihood that they'd face an annual bill of £350 - £500 just to keep the DPF operational, on top of regular maintenance.

As I said, I have no problem if you buy a car with a 100% known usage and service history that you only intend to run on longer journeys (even if they are infrequent and the overall mileage is not that high [which is the type of driving I often do]), but this situation in combination is rare, as most people who do well under 10k miles a year normally make up that driving with shortish trips from cold.

Reliable DPFs and EGRs - Gibbo_Wirral

I think the problem comes for people who drive essentially the opposite to you, but erroneously think that because they're driving a diesel that it must be more economical on ANY run that a petrol driven car.

Spot on. I went from a 2003 2L diesel to a 2010 1.4 petrol and found I was still getting the same sort of MPG. My first petrol since around 2001.

I imagine the newer petrol engines are even more fuel efficient.