DPF Issues in Brisbane Jeeps: Exhaust Filter 100% Full - Service Required See Dealer

Understanding Diesel Particulate Filters (DPFs) in Jeep Vehicles

It’s the Jeep/Chrysler way of telling you the DPF (Diesel Particulate Filter) is completely blocked.

What it means in plain terms:

• The DPF has reached maximum soot load (100%).
• The ECU has disabled further regeneration attempts (it won’t even try to burn it off anymore).
• The vehicle may enter limp mode (reduced power, limited RPM) to protect the engine and turbo.
• Driving it like this can cause engine damage and may damage the DPF beyond recovery if ignored.

Why it happens:

• Repeated short distances and quick trips prevent the DPF from reaching the temperature required for passive regeneration, stopping regeneration cycles halfway.
• Faulty engine components such as DPF pressure sensors, temperature sensors, or issues with the EGR system.
• Excess soot and diesel particulate matter caused by other faults like a stuck EGR valve, injector problems, intake manifold runner or turbocharger issues.

What needs to be done:

• A DPF Assessment (Part A) involving scan tool checks, live data logging, sensor testing, and visual inspection. Here's a link to our Assessment process
• If the filter is suitable, proceed with an On-Vehicle Chemical DPF Clean (Part B) to flush out soot and ash, restoring exhaust flow. Here's a link to our chemical cleaning process
• Followed by a road test and regeneration cycle to confirm that pressures and temperatures return to specification.

👉 If the filter is too damaged or loaded with ash, replacement with a new DPF might be the only option — but most cases can be saved with proper diagnostics and regular maintenance.

The Link Between Intake Runner Faults and DPF Blockages in Jeeps

One of the most common DPF-related issues in Jeep diesel vehicles is a fault with the intake manifold runner, often referred to as the swirl flap fault. These faults typically trigger diagnostic trouble codes such as P2006, P2007, P2015, P2016, or P2017.

The connection between intake runner faults and DPF blockages is straightforward:

• When the intake runner malfunctions, the engine combustion process becomes less efficient, resulting in incomplete fuel burning.
• This inefficiency produces extra soot particles, which are then pushed directly into the DPF filter.
• Simultaneously, the active intake runner fault signals the ECU that the engine is experiencing a problem.
• In response, the ECU often blocks or restricts the DPF regeneration cycles, preventing the filter from burning off the accumulated soot.

This combination of increased soot production and inhibited regeneration leads to the DPF becoming fully blocked, triggering the “Exhaust Filter 100% Full – Service Required” warning that many Jeep owners encounter.

At Clean Flow DPF, we frequently observe this cycle. By repairing the intake runner fault or, where appropriate, using software to program out the fault code, we enable the DPF to regenerate properly. This approach helps prevent recurring blockages and restores the Jeep’s reliable performance.

Common DPF Issues Experienced by Jeep Owners in Brisbane

1. Blocked or Clogged DPF

Frequent short trips and stop-start driving in Brisbane often prevent the DPF from reaching the high temperatures needed for passive regeneration, causing soot to accumulate and block the filter. Blocked DPFs can cause engine problems due to high back pressure.

2. DPF Warning Light Activation

When the DPF becomes blocked, the vehicle’s dashboard will typically display a warning light indicating that the filter needs attention. Ignoring this light can lead to further engine problems. Driving for 30 to 50 minutes at sustained speeds can help clear a DPF blocked by soot.

3. Faulty Sensors and Contaminated Engine Oil

Malfunctioning sensors or using incorrect engine oil can accelerate DPF clogging by increasing ash accumulation or causing false warning signals. A clogged DPF can lead to expensive repair costs if not attended to promptly.

How Does the Regeneration Process Work?

DPF regeneration is the process of burning off the collected soot to clear the filter. There are two main types:

• Passive Regeneration: Occurs naturally when the vehicle is driven at sustained higher speeds and exhaust temperatures are sufficient to burn off soot.
• Active Regeneration: Triggered by the vehicle’s engine control unit when soot buildup reaches a certain level, involving the injection of extra fuel to raise exhaust temperature and burn off soot.

Most modern diesel cars manufactured after 2009 are fitted with a diesel particulate filter.

The primary function of a DPF is to reduce harmful emissions from diesel engines.

If neither process completes successfully, the DPF can become blocked, requiring professional cleaning or forced regeneration.

Tips for Maintaining Your Jeep’s DPF in Brisbane

• Regularly Drive Longer Distances: Taking your Jeep on highway trips helps the DPF reach temperatures needed for passive regeneration.
• Use Correct Engine Oil: Follow manufacturer recommendations to avoid ash buildup.
• Monitor Warning Lights: Address DPF warning lights promptly to avoid costly repairs.
• Schedule Regular Maintenance: Have your DPF inspected and serviced by qualified technicians familiar with Jeep diesel engines.

When to Seek Professional Help

If your Jeep’s DPF warning light remains on despite longer drives, or if you notice reduced engine performance or increased fuel consumption, it’s important to have your vehicle inspected. Our fully mobile service offers professional diagnostics, forced regeneration, and chemical cleaning to restore DPF function conveniently at your location.

Conclusion

If your Jeep shows “Exhaust Filter 100% Full – Service Required” on the dash, the issue often runs deeper than the filter itself. One of the most common root causes we see is an intake manifold runner fault, which creates extra soot and blocks regenerations, leaving the DPF overloaded.

At Clean Flow DPF, we specialise in getting to the bottom of these faults. By combining a full diagnostic assessment with professional on-vehicle chemical cleaning — and offering proven software solutions for intake runner problems — we fix both the symptom (a blocked DPF) and the cause (engine faults that stop regenerations from working).

That’s why so many Jeep owners across Brisbane rely on us when the dash lights up — we solve the problem properly and keep you moving.

Contact Us

For expert advice and professional DPF maintenance services tailored to Jeep diesel vehicles in Brisbane, get in touch:

Phone: 0440 132 640 Email: info@cleanflowdpf.com.au Location: Brisbane, QLD

Keep your Jeep running clean and efficiently with the right DPF care.