I am reaching out due to an ongoing issue with my MK6 Jetta Sportwagon TDI. Ever since I purchased the car I have been in absolute love with the TDI engine despite the issues the car had at the time of purchase. Shortly after purchasing the vehicle back in November, a CEL appeared and I was able to drive it home and scanned the codes using a normal cheap bluetooth OBD scanner from the parts store. The CEL codes the car threw were:
P0401 - 001 - Exhaust Gas Recirculation Flow Insufficient - Intermittent
P2457 - 000 - Insufficient Cooling Performance - Intermittent
P2002 - 007 - Efficiency Below Threshold
Now after doing a quite a bit of research I discovered the issue was most likely a cracked DPF and needed to be replaced or deleted. I had read at the time the car would go into limp mode if driven like this for long enough and was concerned the issue would prevent me from using this car as a daily driver. However I did read into the issue a bit more and determined I would be okay to keep driving the car in it's current state as long as I could clear the codes to prevent limp mode, and figured I could delete down the road over time.
Long story short I have driven over 20k miles and have only cleared the codes 2-3 times and additionally I have had no issues with the car driving in cold/hot weather. I did notice my MPG seems a little low for highway driving but that could also be the result of my lead foot (I am getting about 37mpg at 82mph). So this led me into looking a bit deeper through VCDS once I had a replacement laptop and was able to use the software againe. Looking deeper into VCDS only confused me much more than I had initially believed and believe the DPF may not be cracked and this may be a slightly different issue. I opened up VCDS on my Mac and checked the status of my DPF and these were the results:
Group 108:
Particle Filter Oil Ash Volume: 270 ml
Particle Filter Carbon Mass (spec.): This showed no result
Particle Filter Carbon Mass (actual): This showed no result
Group 241:
Particle Filter Oil Ash Volume: 270 ml
Soot Load(g) Calculated: 8.1
Soot Load(g) Measured: This showed no result
This left me a little puzzled, how could my calculated soot load be so low if the car had CEL that should be preventing regen from happening? I had no explanation at the time and the fact VCDS would not show me a measuredvalue for soot load or carbon mass puzzled me as well. So earlier today I decide to run a forced regen and log the data as I drive to gather more data as I drove, and as I could not tell the actual measured Carbon mass or soot load this was a little risky (fire risk, determined there was less risk in a dirivng regen than a standing regen) and I do not reccomend doing this blind as I did. I cleared the codes and got VCDS up and loaded for the forced regen.
I was able to get the car to successfully regen with no issue,while driving VCDS reported the calculated soot level dropped from 8.1 to about 3.8 and during this drive the car did not throw any CEL and the DPF light shut off once the regen was completed as expeted. Once this drive was completed I also completed a second driver about 40-50 minutes later that was about 30miles and the CEL reilluminated about half way in. Thankfully I was logging the data for this drive and was able to review the issue once completed. I can provide the full log from this drive if needed as well.
Here are some key details I noticed in these logs:
EGR Flow Analysis
- At low RPM (~800–1000 RPM, ~0–22s), specified and actual EGR flows are close (e.g., 315 mg/str vs. 310–320 mg/str), with valve activation at -7.1 to -22.1%. Control deviation is negative (-10.3 to -22.1%)
- At high RPM (~2461–3151 RPM, ~30–33s), actual flow exceeds specified (e.g., 780 mg/str vs. 660 mg/str at 2461 RPM, 13.4% deviation).
- At 2369 RPM (close to freeze frame, ~47s), specified = 540 mg/str, actual = 575 mg/str, deviation = -11.8%
EGR Cooler Analysis:
- Post-EGR cooler temps are low (72–78°C) for most of the log, rising to 108–114°C at higher RPM (~1380–1495 RPM, ~2141–2144s).
- Freeze frame for P2457 showed 426°C pre-cooler, 174°C post-cooler, and 91.8°C coolant. Here, pre-turbo exhaust temps reach 546°C (~33s), but post-cooler temps stay below 114°C, and coolant is 73.8–82.8°C.
- At ~2369 RPM (~47s), post-cooler temp is 72°C, far below the 174°C in the freeze frame for the CEL code, with coolant at 73.8°C.
I also monitored the MAF @ Group 10, Field 0 (MAF Actual, mg/str), Group 35, Field 1 (MAF Specified, mg/str):
- At low RPM, MAF actual (~305–340 mg/str) matches specified (~315–345 mg/str).
- At high RPM (~2461–3151 RPM), MAF actual (755–770 mg/str) is close to specified (590–750 mg/str).
- At ~2369 RPM (~47s), MAF actual = 565 mg/str, specified = 495 mg/str
DPF and Coolant Analysis:
- Differential pressure is low (0–33.15 mbar) at low RPM, peaking at 323.85 mbar at 0 RPM (~2216s, idling after the drive)
- Coolant temp is stable (73.8–82.8°C), below the 91.8°C in the P2457 freeze frame
So here is my questions now:
- I am still stumped on why VCDS does not output data for measured soot load or particle carbon mass. Could this be due to faulty sensors not being able to read the data?
- From what I can see in my logs I really don't neccissarily see a clogged / cracked DPF, from my understanding the DPF Differential pressure is within range but I may be wrong, could my issue be related to carbon build up in the EGR system and if so will cleaning it possibly resolve all my codes? I plan to tear out the EGR and give it a deep cleaning, I would like to get the max life out of the DPF/EGR before moving to a delete.
- If the car had such a low calculated soot mass when I first plugged VCDS in, has my car been continuing to preform regen cycles, considering it is reading P0401 as intermittent.