My 2012 Toyota Rav4 with just over 60k miles threw a DPF code P2002. I’ve had it for 5 years (and done 20k in that 5) and do a few long journeys and hardly any town driving. To date its been main dealer serviced and totally reliable.

Anyway I did a 2h15m drive mostly on dual carriageway and motorway. Stopped for 30mins, drove off and the dash lit up. Fortunately at this point I was near home and the car limped home struggling to maintain speed on any gradient.

Younger son works in a small independent garage and they said they would trigger a forced re-gen. When they tried the car gave them “the finger” and refused to re-gen. The tool said complete immediately. Suspect the DPF is not blocked.

Main dealer said they would 1. Force Regen, 2. Terraclean 3. Replace, at their rates quite pricy.

I’ve booked a Terraclean elsewhere (probably the same sub-contractor as the main dealer).

Any thoughts as to my options after if the code is still present. The DPF pressure sensor is cheap enough and easy to replace.

I’m quite a good with tools (built kits cars and serviced many older cars in my younger years). DPF from a factor is about £500 but as I mentioned earlier I can’t see why it should be blocked.

Thoughts anyone. EGR clogged ?

I really like the car but currently a bit annoyed at it. I can afford the repair costs, but rather not, but my own time is limited.

Thanks in advance.

Clogged EGR wouldn’t (shouldn’t) cause a false flag for the DPF, but a clogged delta-pressure sensor could. There will be a pressure sensor either side of the DPF that is used to detect when it is too-full (and also when it’s not there at all). If for some strange reason the rear one is clogged up, it would be reporting a high delta pressure across the DPF and so think that the can is full. They are usually easy to access and it’s just an air line to a sensor so I’d say first thing is pop those off and clean them out then go from there.

As above I’d look at the pressure sensor or if there’s a pipe from the sensor to dpf as that may clog.

If it turns out the rear sensor line is clogged, it’s worth checking the rear DPF face as well – the exhaust coming out should be clean of soot (the whole point of the DPF) and so there shouldnt really be anything to clog the sensor line up with… If the line is clogged with soot it would indicate a cracked DPF which should be checkable by seeing if there are any soot deposits on the rear face and surrounding exhaust. If there is that suggests a crack and would need a new DPF.

I’m just going through DPF issues. Getting errors on screen – a trusted Indy garage said they got a code but couldn’t find a solution, even with Google, so they suggested the local main dealer. Main dealer said they couldn’t resolve it, or even tell me how as Peugeot didn’t know (charged £50 for that though). Back to Indy, and it’s a new code now, saying there’s a problem with the spark plugs . . . on a diesel.

A bit more Google and apparently although it says spark plugs, it probably means a faulty glow plug. Apparently, as glow plugs are essential to the regen process, if they’re not working you get a DPF error. Back with the Indy now and he’s checking for me. Fingers crossed.

I had similar issues a year or 2 ago. Looked like just a sensor, but changing the sensor + forced regen didn’t solve it. Unfortunately a new DPF did, the price hurt. That was a 6/7 year old Mondeo that generally did long trips

I’ve also had a DPF go on a 6-month old Vito. Luckily that was warrantied, but it also done almost exclusively long trips (that one must’ve been faulty from new though)

The cheaper place you’ve booked, how much cheaper is it actually – i.e, is it cheap enough that you can stomach paying for them not to fix the problem and have to go to the main dealer anyway (especially if the indy your son works at couldn’t fix it).

And if the main dealer discovers it’s something else, then you can still shop around (if it’s worth it).

We had an ultrasonic clean on the DPF on our 2009 Rav4. Drive in place who took it off, cleaned it and showed it to me and reinstalled, fixed codes and increased MPG. The fed us coffee and sausages whilst we waited.
That was in Germany on hols in 2018, I tried to find a drive in place in the UK for my friend last year but no luck.

Actually I have just found this guy near me, I think its a franchise.

https://dpf-medic.co.uk/

Long time lurker, first time poster!
P2002 is failed DPF, usually this means cracked. 2012 vehicle so the diagnostic is likely to be based on the pressure drop across the DPF rather than a particulate sensor after the DPF.
So 2 options here, failed pressure sensor or failed filter.
Have a look around the tailpipe and see if there are signs of soot, if you see soot it’s likely the filter has cracked.
For the pressure sensor check the hoses/pipe are connected. If the upstream pressure hose has become detached it might cause P2002 to flag.
The forced regen is likely to be inhibited due to P2002, so I doubt the main dealer will be able to trigger a service regen. Cleaning won’t help a cracked filter either! So if it is broken your looking at a replacement. I changed the DPF on my berlingo in the street with normal hand tools, it was quite straight forward. If you go down the DIY route it will be a question of access and how easily the exhaust comes apart! You’ll also likely need to tell the car that it’s had a new DPF fitted, this is usually a dealer diag routine.
Hope this helps.

You could do worse than find you nearest DPF Doctor franchised workshop.

https://the-dpf-doctor.com/find-an-accredited-member/

My best mate has done all the training and is an accredited member and talking about it with him there is a gulf in knowledge and ability between your average workshop and main dealer, with those who have made DPF problem analysis their main business. He reckons almost everyone who comes to him can’t believe how cheap it is compared to the money they will have already wasted going down the normal route used by dealers etc. Plenty of tails of replaced DPFs only to have them block after a few hundred miles as they were never the problem.

Thanks all. As I said Terraclean booked for tomorrow. I’ll update you later. Fingers crossed. But not hopeful.

For the pressure pipes also check neither have burnt out, my Mondeo burnt one and turned it to ash, I replaced with silicone for buttons and its been fine since. Just make sure you get the correct inner diameter, one was 3mm and the other 4mm, I did both to be sure, pipe was from autosiliconehoses.

Check the two hoses aren’t leaking (get under car, unclip hoses, you shouldn’t be able to blow through them).
Check the two hoses aren’t blocked (remove hoses from sensor, then get under car, you should be able to blow through them).
Try to source a working sensor from a mate with a car with the same sensor, or splash out on a new one (not usually that expensive).
If problem persists talk to a DPF specialist who will be cheaper than the main dealer as they don’t want to substitute parts at your expense until they happen on a solution (Moi? Bitter? Non)

DPF houses are pristine. But EGR has failed. The garage can test / trigger it but it remains inactive.

New one due in tomorrow. Update then. Thanks All

Intriguing let us know how you get on.
I’m going to preface this by saying I’m not a Toyota Diesel engine expert but…
The only scenario I can think of where an EGR fault causes P2002 to flag is if the EGR fault throws out the exhaust volume/mass flow calc.
When you say the garage can test/trigger, do you mean they can drive the EGR valve via their diagnostic tool? If so that suggests the valve is ok but the control system is inhibiting the EGR, but perhaps I’ve misinterpreted your meaning.
Anyway fingers crossed they solve it.

EGR replaced, Codes cleared. Terraclean done.

Car drives OK now. Let see how it behaves in the coming weeks and is able to do a regen when required.

While it’s working fine take it for a very long drive! Make sure you have break down cover before you set off! Good luck.

That’s great news OP. As Damascus said put some miles on it now to validate the repair.