2006 V10 dpf delete questions

dumpybunny · Feb 22, 2014

looking for some first hand info on what it takes to remove the dpfs on a 2006 v10. i am a machinist and a fabricator so the plumbing will be no issue and i understand i will need a custom tune, more of what im looking for is what other components/sensors can be removed, have to be removed or have to stay in place.

NOTE: i am NOT looking for reasons on why i shouldn't be removing my dpf, the reasons that they are there, or environmental concerns!!!

thanks

Mike N · Feb 23, 2014

The guts of the DPFs is a ceramic honeycomb similar to modern catalytic converters. The easiest 'removal' process is to remove the DPFS and using a steel bar or similar break up and remove the ceramic then bolt the empty shell back in place. Visually no one will know you removed them. I'm sure you know that you will need a tune or you will get a CEL and still get regens.

dumpybunny · Feb 23, 2014

Mike N said:
The guts of the DPFs is a ceramic honeycomb similar to modern catalytic converters. The easiest 'removal' process is to remove the DPFS and using a steel bar or similar break up and remove the ceramic then bolt the empty shell back in place. Visually no one will know you removed them. I'm sure you know that you will need a tune or you will get a CEL and still get regens.

I dont want the easy way, i want to physically remove the DPFs in one piece rather than destroying them. Im not worried if anyone can visually tell if the DPFs have been removed. I want to have the minimum components necessary instead of making bungs for sensors i dont need

Mike N · Feb 23, 2014

Its your car you can do it however you want but Truthfully it's harder to make the replacement pipe. Where are you going to get the VW exhaust flanges from unless you rob them from the DPFs you take off. Just put the sensors back in the DPFS when you reinstall them. The hardest part of the job is getting the hard to reach and heat cycled bolts loose.

dumpybunny · Feb 23, 2014

Mike N said:
Its your car you can do it however you want but Truthfully it's harder to make the replacement pipe. Where are you going to get the VW exhaust flanges from unless you rob them from the DPFs you take off. Just put the sensors back in the DPFS when you reinstall them. The hardest part of the job is getting the hard to reach and heat cycled bolts loose.

Im a cnc machinist and can make flanges as well as any other components to do the delete. I intend on building a complete turbo back exhaust from scratch so i have no desire to keep the dpf shells on the car, id rather keep them in one piece in the even i want to sell the car and/or put it back to stock.

nickm · Feb 23, 2014

I don't have any advice on the physical removal, but you'll need software for this to actually work. People on here have had success with Malone tuning. It may be worth reading some of those posts or having a discussion with Malone to see what they have to offer.

If you don't update the software the vehicle will still run as if DPFs are in place - this is undesirable for a number of reasons.

It would be great if you could share your end product and results with us all.

zagg · Feb 23, 2014

JEGS, an online auto parts store has a lot of blank parts for making your own custom exhaust.

dumpybunny · Feb 23, 2014

nickm said:
I don't have any advice on the physical removal, but you'll need software for this to actually work. People on here have had success with Malone tuning. It may be worth reading some of those posts or having a discussion with Malone to see what they have to offer.

If you don't update the software the vehicle will still run as if DPFs are in place - this is undesirable for a number of reasons.

It would be great if you could share your end product and results with us all.

i am pretty much trying to find out what sensors will be needed once a dpf tune is in place. i figured i would post here first and get as much info as i can before i talk to a tuner about the specifics.

zagg said:
JEGS, an online auto parts store has a lot of blank parts for making your own custom exhaust.

i am a cnc machinist so all of the components will be no sweat for me to machine and fabricate, im just looking for what sensor provisions i will have to include on my custom dpf delete pipes.

zagg · Feb 23, 2014

I know some others on here have done it. I have to check through my posts to find who they were.

dumpybunny · Feb 23, 2014

and just so everyone is clear, i am not trying to do this the fast or easy way. i have a strong attention to detail and dont hold that back on my cars. for example, i wasnt liking the VW badge on the hatch of my touareg so i machined my own from a piece of 304 stainless steel.

zagg · Feb 23, 2014

Clint440 posted this,"I went with the EGR tune, DPF delete, and slight power upgrade. No issues over the past 7,000 miles plus. Fuel economy is better, definitely noticeable power increase. What I like most is the simplification/increased reliability, no more DPFs and related sensors to worry about and less soot in the intakes.".....you may want to contact him. And I know that Les at DieselDubs, check online, did do a V10 DPF delete with Malone tune. I would call him he is very easy to talk to.

dumpybunny · Feb 23, 2014

zagg said:
Clint440 posted this,"I went with the EGR tune, DPF delete, and slight power upgrade. No issues over the past 7,000 miles plus. Fuel economy is better, definitely noticeable power increase. What I like most is the simplification/increased reliability, no more DPFs and related sensors to worry about and less soot in the intakes.".....you may want to contact him. And I know that Les at DieselDubs, check online, did do a V10 DPF delete with Malone tune. I would call him he is very easy to talk to.

awesome, thank you! being that im new to this forum thats the kind of stuff i was hoping to find or someone on here would know of:clap:

clint440 · Feb 23, 2014

There is just one sensor/bung on the DPF itself. The tune deactivates everything else involved in regenerations. The hardest part was just unbolting the DPFs. I went with Malone.

nickm · Feb 23, 2014

dumpybunny said:
i am pretty much trying to find out what sensors will be needed once a dpf tune is in place. i figured i would post here first and get as much info as i can before i talk to a tuner about the specifics.

Makes sense - Malone tuning is definitely the expert tuner as far a DPF delete is concerned, I know if 5 V10s that have his tune and its been perfect. I think you'll love the way it'll run with a tune, I certainly loved the way my 04 ran post tune....didn't have DPFs on the 04 so i never had to worry about the delete part.

Nice work on the VW badge.

johnnys1957 · Feb 28, 2014

I would recommend the following:

1) you remove the DPF exhaust pipe section, bandsaw the the DPF at the outlet cone and carefully drill out each of the ceramic plugs in the alternating channels of the DPF substrate. This will allow the engine exhaust gas to flow directly through the DPF substrate without trapping diesel particulate matter. The DPF outlet cone can then be carefully re-welded to make the DPF exhaust pipe section appear stock.
2) you remove the DPF exhaust pipe, cut the exhaust pipe at the DPF outlet cone and use a hole saw/core drill to drill a 2.0" diameter hole through the center of the DPF substrate. The DPF outlet cone can then be re-welded to make the DPF exhaust pipe section appear stock.
3) you remove the DPF exhaust pipe, cut the exhaust pipe at the DPF outlet cone and bash out the DPF substrate with hammer and chisel. Make sure that you remove all of the ceramic DPF substrate material. The DPF outlet cone can then be re-welded to make the DPF exhaust pipe section appear stock.

Please note that the VW exhaust pressure sensors will probably be measuring DPF differential pressure and absolute pressure, therefore modifications 2) and 3) may not be restrictive enough to fool the pressure sensors A smaller diameter hole saw/core drill size or exhaust flow restrictor plate inside the empty DPF shell may be required. These mods may save you $4k.

2006 V10 dpf delete questions

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dumpybunny

Mike N

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nickm

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dumpybunny

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nickm

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