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Aftermarket Diesel Particulate Filter (DPF) for a 2005 E60 530d.

Greetings, esteemed E60 enthusiasts. I have predominantly owned high-performance petrol E39 models, including a few 330i variants. However, I later acquired a CLK 3.20 and subsequently a 220 cdi, which I quite enjoyed, except for the persistent issue of rust. Consequently, I embarked on an extensive search for a well-maintained E60 530d, and fortunately, I found one in impeccable condition just 7 miles away from my location. The vehicle boasted a comprehensive service history, with 132,000 miles on the odometer. Although it did have some minor problems, such as the swirl flaps being locked in the open position, I was aware of this during the test drive. Regrettably, due to driving it at night, I was unable to observe the significant smoke cloud it emitted. Nevertheless, the performance of the vehicle rivalled that of the finest petrol engines.

Question - It seems that most people on this platform are interested in removing the diesel particulate filter (DPF), but I am interested in reinstalling it. I own a 55-plate 218bhp version of the vehicle. My garage advises against reinstalling the DPF, but I dislike the excessive black smoke produced at 3000+ revs. Nowadays, good aftermarket filters are available for only 160 quid. However, my main concern is whether I will need to restore the electronic control unit (ECU) to its original state or if cleaning the car's exhaust system will suffice. I regularly commute 100 miles on motorways.

If necessary, I am willing to change these filters every 2-3 years. It is comparable to purchasing a high-end phone such as the Apple iPhone 10, where you could purchase 4 Xiaomi Note 7 phones for the same price.

Is it possible for the tuners to reprogram using the original BMW files? What are the associated expenses?

It seems that I may sell the empty diesel particulate filter (DPF) for a higher price than a new aftermarket DPF that is already full. Additionally, the empty DPF is more inconspicuous when it comes to passing certain tests. However, I must clarify that I am a beginner and lack knowledge in this area.

Can any of you suggest a reputable aftermarket brand or supplier? I am looking to maintain my vehicle in pristine condition and I really like its style.

I cannot suggest a specific aftermarket filter, but it is necessary to examine and perhaps re-map the engine's control unit (ECU) to ensure the functioning of the regeneration process. Failure to do so may result in the filter being clogged quickly.

I typically reinstall the regen software every 2-3 months when there are no regenerations occurring. Additionally, there seems to be another issue since the emission of smoke should be little, if any.

I agree with this statement. It is quite probable that there was incorrect mapping when the Diesel Particulate Filter (DPF) was removed. Since these lambda-regulated engines are designed to operate with precise air-fuel ratios, they would not emit significant amounts of soot even without a diesel particulate filter (DPF).

Last week, I had the swirl flaps repaired. They had been left in the open position for a long time.
The tapits seem to need maintenance, and the emission of black residue only occurs when pressure is applied to the foot. However, it should be noted that the vehicle's performance was much enhanced, maybe due to the installation of a stage 3 upgrade, as suggested by a BMW technician. Could this modification be responsible for the excessive soot accumulation?
Frankly, the use of stock power would be acceptable.

I believe that there is no proprietary formula for creating a suitable and dependable diesel particulate filter (DPF), therefore I would not hesitate to purchase from a different manufacturer (on trusted online platforms, naturally). However, I am interested in knowing which aftermarket models you saw that were really less expensive than a pre-owned, unbranded Diesel Particulate Filter (DPF). Their typical range is typically between 400 and 650, as per my most recent observation.

Black smoke indicates incomplete combustion, which is not expected even in the absence of a Diesel Particulate Filter (DPF).
I would investigate any boost leaks or examine the fuelling on the map.

Thank you for your input. I have spoken to other individuals in the craft who own garages, and they have provided the same advice as mentioned above. They all agree that the addition of the Diesel Particulate Filter (DPF) was a significant design flaw in this particular model. The early versions of these cars often have the DPF removed because when it is in place, it causes numerous engine problems and the cars frequently require repairs. However, if the removal is done correctly, it has minimal impact on emission testing and the cars still meet the specified tolerances. Therefore, I fail to understand why there is such a big concern about removing the DPF.

All diesel particulate filters (DPFs) are ineffective and fail to fulfil their intended purpose. While they do prevent soot emissions, they also disrupt the proper functioning of the vehicle, thereby rendering them counterproductive.

I was informed that MOT stations cannot fail vehicles if the DPF cases are left intact, even after a knock test. This is because the testers do not possess X-ray vision, nor are they expected to. Additionally, they are not paid extra to inspect these cases. However, in order to ensure my compliance with road regulations, I have decided to have a new DPF fitted next week at a cost of £180, including installation. I will also have a new remap done, without any modifications, just the stock version. If I encounter any issues, I may consider trading in the vehicle and attributing it to a poor choice. Nevertheless, I understand why many individuals choose to delete or gut the DPF on this particular car. The only downside is that very few cars drive as well as this remarkable one. I tested a new car yesterday and found it to be lacking in both performance and character compared to my old one!

The MOT testers have observed that many second and third owners are unaware that their cars' diesel particulate filters (DPFs) have been removed (I was one of them, haha). The testers do not inform the owners of this for obvious reasons. One tester estimated that around 90% of BMW DPFs are removed during testing, and the remaining ones are often temporarily reinstalled just for the test. This is evident from the fresh marks on the bolts indicating recent removal and reinstallation.

Last night, I heard a humorous anecdote about an elderly car owner who had possessed his 2004 vehicle for numerous years. After his most recent service, he enquired why he, unlike many other owners, had never experienced the troublesome issue of diesel particulate filter (DPF) problems. It turned out that the garage personnel, rather than his MOT testers, provided him with the explanation. The owner exclusively drove within the confines of the inner city. There is no content present in your possession, which has been completely removed. This is advantageous for you. Another individual had it replaced, which serves as evidence that if no one informs an additional owner of a removed diesel particulate filter (DPF), and it successfully passes multiple Ministry of Transport (MOT) tests, it becomes difficult to establish knowledge of its initial removal. Additionally, certain CLK models do not have a DPF, despite Mercedes' claims, and Civics did not possess them until 2010.

The garage professionals have consistently informed me that a stock map/file is more effective than a chipped or stage 1, 2, or 3 remap. They believe this plays a significant role in preventing DPF blockage.

Thank you for your assistance up to this point. I will provide a report and provide you an update.

Understanding the causes behind the DPF's failure to regenerate makes it simpler and more cost-effective to resolve the issue, without resorting to completely removing the component.
Primarily, the issue is often caused by malfunctioning thermostats in BMW vehicles. A regeneration process, which is necessary for the vehicle's performance, will not occur if the temperature is below 70 degrees Celsius. However, even at this temperature, the temperature gauge will still indicate a normal reading, leaving the owner unaware of the underlying problem.

Previously, this statement was accurate. However, the Ministry of Transport (MOT) regulations have been updated for automobiles equipped with a Diesel Particulate Filter (DPF). These vehicles are now prohibited from emitting any smoke during the test.