18/09/2026
134% DPF soot load… but barely any backpressure. Something wasn’t adding up. 👀🔧
This Astra came to us after repeatedly failing its MOT emissions test and throwing out serious black smoke.
The scanner was telling us:
💨 134% calculated DPF soot load
❌ 27 aborted regenerations
📉 But the pressure readings didn’t match a heavily blocked DPF
✅ EGR operation checked
✅ Turbo boost actual vs desired checked
✅ VNT position checked
✅ MAF / airflow data checked
✅ DPF pressure sensor response checked
❌ Forced regeneration wouldn’t complete
Instead of just replacing parts, we followed the data.
The ECU thought the DPF was heavily loaded… but the exhaust simply wasn’t showing the backpressure you’d expect from a filter that blocked.
So we went one step further.
Borescope into the DPF. 🔍
And there it was — the filter substrate had been drilled/removed through the centre, allowing exhaust and soot to pass straight through.
That explained everything:
➡️ Low restriction
➡️ Black smoke from the tailpipe
➡️ Strange soot calculations
➡️ Failed regenerations
➡️ Failed emissions test
We got the emissions system put right and sent it back for its MOT.
PASS ✅
From failed emissions to a clean MOT pass.
That’s the difference between reading a fault code and actually diagnosing a vehicle.
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