VW Crafter NOx Catalyst Failure & Exhaust Issues

I had a comparable issue with my 2018 VW Transporter last year. Having some experience with diesel engine problems, I recognized similar symptoms, check engine light and exhaust system warnings. Initial car diagnostics revealed elevated NOx emissions and a leak in the exhaust system near the catalytic converter. The workshop found that the NOx catalyst had developed cracks, causing both the emissions issue and the leak. These components are critical for proper exhaust gas treatment and emissions control. The automotive repair involved replacing the damaged NOx catalyst and securing the surrounding exhaust components. Total cost was 265€ for parts and labor. Since the repair, the system has worked flawlessly with no error codes or emission problems. To better assist with your specific case, could you share: Current mileage on your Crafter, Whether you notice any performance issues, If you have any diagnostic codes available, Are there any unusual sounds from the exhaust area This information would help determine if your issue matches what I experienced and whether similar repairs might be needed. Regular inspection of the exhaust system can help catch these issues early. Proper maintenance of the NOx catalyst system is essential for meeting emission standards and optimal engine performance.

Thanks for your reply and info. My Crafter has 199641KM on the odometer, last serviced 2 weeks ago. The performance seems normal but the noise from underneath is concerning. I have the fault codes now, P2202 and P0401. The loud exhaust sound started after a long highway trip last week. Our regular maintenance schedule has been consistent, so this NOx catalyst issue came as a surprise. The fuel efficiency has also dropped noticeably in the past month. Your repair experience gives me hope this might be a straightforward fix. When you mentioned 265€, was that with a new OEM catalyst or aftermarket? The quote I just got is significantly higher at 890€ for parts alone. I will definitely get this checked soon to prevent any further damage to the exhaust system and keep NOx emissions in check.

Thanks for sharing those details. Unlike my Transporter repair where costs were lower, your Crafter situation seems more complex. My quote was for an aftermarket catalyst, the OEM parts are notably pricier, which explains your 890€ quote. The fault codes you mentioned match what I experienced, particularly P2202 which directly relates to NOx catalyst efficiency. The highway trip likely accelerated an existing issue, as extended high-load operation can stress aging catalytic converter components. Your fuel efficiency drop mirrors my experience, I noticed about 15% higher consumption before the repair. The loud exhaust sound also matches my symptoms, though mine started more gradually. Having gone through this, I would recommend: Getting a thorough exhaust system inspection, Checking surrounding components for heat damage, Verifying if the car diagnostics show any additional sensor issues The higher mileage on your Crafter versus my Transporter when the issue occurred likely contributes to the different repair scenarios. While mine was a simpler fix, your catalyst aging might have affected more components in the exhaust system. Given the current fuel costs, fixing this promptly could offset the repair expense through improved fuel efficiency. Plus, proper NOx emissions control is crucial for engine health and performance.

Thanks for the input. After reading through the responses and comparing with my situation, I decided to proceed with the repair this week. My workshop confirmed they will do a complete emissions system inspection before replacing the NOx catalyst. The 890€ estimate for OEM parts makes more sense now compared to aftermarket options. Given the high mileage on my Crafter, investing in quality parts seems worthwhile for long-term air quality compliance and fuel efficiency. The diagnostic codes and symptoms match perfectly with what others experienced. Looking forward to resolving these exhaust system issues and getting back to normal fuel consumption rates. Will make sure to maintain regular checks of the emissions system components going forward to catch any future problems early. Thanks again for all the repair insights shared here. This has been really helpful for understanding the NOx catalyst replacement process and associated costs.