VW Crafter DPF Problems: Smoke, Power Loss & Solutions

I had a similar issue with my VW Transporter T5 2010 (some experience with diesel vans). The symptoms were nearly identical, reduced power, black smoke, and poor fuel efficiency. The engine light triggered after a few unsuccessful regeneration attempts. Initially, I tried the basics, highway driving to force regeneration, but like in your case, it didnt help. The workshop diagnosed a completely clogged DPF, causing excessive backpressure in the exhaust system. They recommended a complete filter replacement rather than cleaning, as the DPF was beyond recovery. The repair cost me 1550€, including parts and labor. Since the replacement, the van runs perfectly, no more black smoke, power is back to normal, and fuel efficiency improved significantly. The engine light hasnt returned. Before suggesting specific solutions, could you share: Current mileage on your Crafter, How long youve noticed the symptoms, Type of driving you typically do (city/highway split), Service history, especially previous DPF work, Any other warning lights or unusual behavior This information would help determine if your situation matches what I experienced and whether a full DPF replacement might be necessary in your case too.

Thanks for sharing your experience. My Crafter is at 134561KM and had its last major service 6 months ago. The diesel filter problems started about 3 weeks before the sensor fault appeared on the dash. The exhaust system seems to be struggling more during cold starts and city driving. My mechanic attempted a forced regeneration twice but both failed to clear the issue. The engine light keeps coming back after a few days of mixed driving. Based on your repair experience, the full DPF replacement might be the way to go. Did you notice any early warning signs before the complete failure? And was there any impact on other engine components from running with the clogged filter for a while?

Thanks for those details. Like you, I noticed early warning signs about a month before the complete failure in my T5. The most obvious was increased fuel consumption and sluggish acceleration, especially during cold starts. Running with the clogged DPF did cause some related issues in my van. The excessive backpressure put additional strain on the turbo and affected overall engine performance. During the vehicle inspection, they found slight oil leakage from the turbo seals, likely due to the increased pressure from the blocked filter. The workshop explained that delaying the filter replacement can lead to more expensive repairs. In my case, they had to clean the EGR valve as it was partially clogged with soot, adding 200€ to the total repair cost. Your symptoms match my experience exactly, failed regeneration attempts, persistent engine light, and poor performance in city driving. The mileage on your Crafter is also in the typical range where these exhaust system issues commonly appear. Since your mechanic has already tried forced regeneration without success, I would recommend getting the DPF replaced soon to prevent any additional damage to other components. After my repair, the fuel efficiency improved by about 15% and the engine runs much smoother, especially during cold starts.

Those symptoms with my Crafter definitely match what you experienced. The fuel efficiency drop and consistent engine light are particularly concerning. Given the failed regeneration attempts and the strain on the exhaust system, I think moving forward with a complete DPF replacement makes the most sense. The backpressure issues during cold starts have gotten worse lately, and I want to avoid any potential damage to the turbo or other components. My typical driving pattern probably hasnt helped since I do a lot of short city trips. I will schedule the vehicle inspection and replacement work this week. The investment in a new diesel filter seems worth it to restore proper engine performance and prevent more extensive repairs later. Good to know I can expect better fuel efficiency afterward, that alone will help offset some of the repair cost. One last question on the repair, did you need to replace any sensors along with the DPF, or was the filter replacement enough to resolve all the warning lights and performance issues?