VW Crafter DPF Sensor Failure Causing Dark Exhaust

I experienced a very similar issue with my 2014 VW Transporter 2.0 TDI. Having some experience with diesel engine maintenance, I initially tried basic troubleshooting but quickly realized this needed professional attention. The symptoms matched exactly what you describe, DPF warning light, failed regeneration attempts, and dark smoke. After vehicle diagnostics, the workshop confirmed a faulty exhaust back pressure sensor was causing incorrect readings, preventing proper emission control system function. The repair cost me 245€, including parts and labor. The workshop performed: Complete sensor replacement, System recalibration, DPF regeneration cycle, Full exhaust system inspection Since the repair, the engine performance improved significantly and all warning lights cleared. No issues with the emission control system for over a year now. Before suggesting specific solutions, could you share: Current mileage, Service history regarding DPF maintenance, Any recent engine work, Error codes from diagnostics scan This information would help determine if your Crafter needs similar treatment or might have additional underlying issues affecting the exhaust system.

Thanks for sharing your insight. My current mileage is 183391KM and I just had a full service last month where they also checked all emission control systems. The DTC error codes point specifically to the exhaust sensor, which matches your experience. Good to know the workshop repair cost and outcome of your similar situation. I will have the sensor tested to confirm before proceeding with replacement. Did your mechanic mention anything about checking related components while doing the exhaust system repair?

Following up on my previous repair experience with the VW Transporter, the workshop actually did recommend checking several related components during the exhaust sensor replacement. The mechanic emphasized that exhaust system issues often interconnect. They specifically examined: DPF condition and soot loading levels, EGR valve operation, Boost pressure sensor readings, Intake air system for restrictions While the exhaust back pressure sensor was the main culprit, they found minor carbon buildup in the EGR valve. A thorough cleaning was included in the quoted price, which helped optimize overall engine performance. Your mileage and recent service history suggest similar causes to what I encountered. The matching DTC codes further confirm the diagnosis. Just ensure the workshop performs a complete exhaust system inspection during the repair, as other components might show wear at this mileage point. Quick tip from my experience: after the sensor replacement, I noticed better fuel economy and smoother acceleration. The car maintenance cost was worth it considering the improved performance and prevention of potential DPF damage. Would be interested to hear if you notice similar improvements after the repair.

Thanks for the detailed responses. I scheduled an appointment with my regular workshop for next week. They confirmed they will do a complete system check including all the components mentioned, DPF, EGR valve, boost pressure sensor and intake system. The quoted price is 280€ for parts and labor, which seems reasonable based on the repair costs shared here. The matching symptoms and error codes give me confidence that the exhaust back pressure sensor is likely the core issue. It helps knowing that addressing this improved both emission control and engine performance in similar cases. Will update the forum once the repair is complete and can confirm if I see the same positive results with fuel economy and acceleration. Really appreciate all the technical insights shared here about proper diagnostic steps and related components to check.