Mercedes-Benz Sprinter How To Fix DPF Filter Clogged

A clogged DPF on a Mercedes-Benz Sprinter is fixed in one of three ways: a regeneration drive that burns the soot off, a DPF cleaning additive in the fuel tank, or a professional clean when the van is already in limp mode. The Diesel Particulate Filter (DPF) on a diesel Mercedes Benz Sprinter traps the soot (diesel particulate matter) left by incomplete combustion, so a Sprinter with a working DPF does not blow visible black smoke.

Every filter has a limited capacity. The Sprinter's engine computer (ECU) measures the exhaust pressure going into and coming out of the DPF, works out how full the filter is, and starts an automatic regeneration when it needs one. Short trips stop that regeneration from finishing, and that is when the filter clogs and the DPF light comes on.

TL;DR

• Cause: soot builds up faster than it burns off, mostly from short trips where the exhaust never gets hot enough.
• Fix 1: a manual regeneration drive, 15-20 minutes in a lower gear at around 1500-2000 rpm, repeated for 45 minutes to an hour and a half in total.
• Fix 2: a DPF cleaning additive in the fuel tank ($13 to $26 a bottle), then a 15 to 30 minute drive.
• Fix 3: if the light stays on, or the van is in limp mode, the DPF needs a professional clean.
• Prevention: high-quality fuel and a regular drive where the engine holds about 2000 rpm for more than 5 minutes.
• If this is not your case, read how to fix a Sprinter AdBlue heater element failure.

Table Of Content

1. What are the signs that your DPF is clogged?
2. How do I unblock a clogged DPF?
3. How do I regenerate a clogged Sprinter DPF?
4. How do I clean a DPF with an additive?
5. How do I stop the DPF clogging again?
6. Why does my Sprinter DPF keep clogging?

What Are The Signs That Your DPF Is Clogged?

• A DPF warning light comes on in the Sprinter dashboard. If the engine management light comes on with it, the problem may be more serious and needs a diagnostic scanner (see the OBD2 troubleshooting guide).

• The engine loses power (limp mode).
• Passive and active regeneration keep failing.
• A strong diesel smell.
• The Stop-Start system doesn't work.
• The Sprinter puts out excessive smoke.
• The engine oil level rises.
• Fuel consumption goes up.

How Do I Unblock A Clogged DPF?

If a professional diagnosis confirms the DPF is clogged, there are two options:

• DPF regeneration
• DPF clean

Neither option is guaranteed to solve the problem for good, because it depends on how you drive most of the time.

If you mostly took short trips before the fix, and you keep taking short trips after it, the DPF light is likely to come back.

How Do I Regenerate A Clogged Sprinter DPF?

1. Automatic Regeneration

In automatic regeneration, the ECU keeps monitoring the exhaust flow through the filter and starts the process at a set point. It adds extra fuel, which raises the exhaust temperature in the DPF, burns off the soot and blows the ash out of the exhaust pipe.

Long trips at higher speed give the high operating temperature and free-flowing exhaust that automatic regeneration needs. If you only use your Sprinter for short local trips, the DPF is unlikely to regenerate on its own.

This is usually when the DPF light comes on. Try a manual regeneration drive before you spend any money.

2. Manual Regeneration

First, check the Sprinter owner's manual (Mercedes-Benz publishes them on its owner's manuals page) for its DPF regeneration instructions. If the manual doesn't cover it, follow these steps:

• Make sure you have enough fuel. The Mercedes Benz Sprinter normally needs at least 25 gallons to start the regeneration process.
• Check for any engine warning lights other than the DPF warning light.

• Warm the engine up to working temperature, then drive for 15-20 minutes at a steady speed in a lower gear on the highway. The rpm should be around halfway, which for most engines is about 1500-2000 rpm at 40 mph.

• Drive for 10 minutes at a slower speed and lower rpm, then repeat at roughly 2/3 of your rpm range for another 15-20 minutes.

• Keep the revs above 1500 rpm during this time. The heat helps clean the DPF, and the Sprinter's regeneration cycle will normally start.
• For best results, keep this cycle going for 45 minutes to an hour and a half. You can spread it over several drives, but make sure the engine is hot by doing at least two sets of 15-minute hot drives each time.

• Make this drive part of your weekly routine before the DPF warning light comes on.

If the DPF light stays on after a manual regeneration, the filter needs a professional clean.

If your Sprinter is in limp mode, the DPF will not regenerate automatically and must be cleaned professionally.

How Do I Clean A DPF With An Additive?

STEP 1: Buy a DPF cleaning additive

The additive breaks down the ash and soot clogging the filter. You can buy one at a local auto parts store or online. They typically cost $13 to $26.

STEP 2: Pour the additive straight into the fuel tank

Read the label and follow the manufacturer's instructions. Switch the Sprinter off, open the fuel tank and insert the additive nozzle. Add the correct amount, then refit the fuel cap and close the flap.

STEP 3: Drive the Sprinter for 15 to 30 minutes

Drive the van as you normally would. The additive works whatever the engine or road speed. If the DPF warning light was on before, it should go out after the drive.

Points to keep in mind with cleaning additives:

• DPF cleaning additives contain fuel-borne catalysts that help burn off the soot and ash.
• Use the additive every 3 to 6 months to keep the DPF clean. Check the owner's manual for how often Mercedes allows it on your Sprinter.
• If the warning light does not go out, take the van to a workshop for a professional DPF clean.

How Do I Stop The DPF Clogging Again?

• Use high-quality fuel. The additives in high-cetane fuel from major brands help burn up the particulates. In the US, diesel quality is set by the EPA diesel fuel standards.
• Low-cost fuel generally makes the problem worse. Better fuel burns cleaner and leaves fewer deposits in the engine.

• Avoid short trips where the engine never fully warms up and the van cannot hold 2000 rpm for more than 5 minutes.
• Use a high-quality fuel additive recommended for the Sprinter.
• Keep the rest of the emissions system healthy too: a failing NOx sensor or worn glow plugs can affect how cleanly the engine burns.

Why Does My Sprinter DPF Keep Clogging?

If the DPF keeps blocking, the cause is usually your driving pattern or the engine running too rich. Either one needs checking, or the DPF will clog again.

The biggest cause is driving a diesel Sprinter mostly around town on short trips, with little highway driving. The DPF collects soot on those short trips and never gets the chance to regenerate.

A regeneration cycle only happens when the DPF and exhaust are hot enough to burn off the soot, which needs the Sprinter to sit above 2500 rpm for 10 minutes or more. That usually means a highway or a long open road.

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