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Stranded at Leh: My Thar suffers a level-3 DPF failure without warning

17th August 2022, 17:14 by Rahul Nagaraj

Once the diesel particulate filter accumulates 37g of soot, the tech team has to step in. Mine had collected 71g of soot mass.

BHPian wooka recently shared this with other enthusiasts.

Got the infamous E21 issue today.

This is after a drive from Noida through Chandigarh, Kashmir, and now to Leh.

Ran through a little bit of a watery patch in the hills above the Amarnath base camp. About 1'. Got this error 6 hours later as I was parking in Leh..

Any ideas? The last servicing was at 9.5k km, DEF was completely topped up. I'm at 15.3K km now. Is it a NOX failure pump or just DEF fluid running out?

I'm stuck at Leh thinking about the onward journey to Nubra and Pangong! How much time do I have before E21 goes to E22(800kms left at E2)?

Could anything ruin the show so poorly that I'm totally stuck (no engine ignition allowed)?

I can't find any Mahindra service points on the map here.

Mahindra Thar DPF Failure Update 1

E21 has devolved to E22.

It went from 800 km to 750 left in just 20 km on the road! Scary for one up in the hills.

At Mentokling Motors in Leh now. Hoping for a quick resolution!

Mahindra Thar DPF Failure Update 2

The E22 issues seem to be random clogging. I believe personally that the valve is not designed well!

The engineer has connected a diagnostic laptop. The SCR routines are running.

Explanation - they're forcing the valve open via the laptop through repeat efforts, I don't see how this valve is not replaced if such issues come up! It's bound to repeat itself.

First, the valve was cooled down. Despite the engine being off for 1.5 hours, it was over 80C. So water was poured on it.

Subsequently, the sensor was whacked with an Aluminium spanner.

Pray, it's clicking away now with the laptop connected. Been 10 minutes. I will post updates as they come.

I'm sure this will be of help to many who face E21/22 issues with their Mahindra vehicles. Do not confuse E2x with E3x. E3x is for low DEF. You can drive the car for up to 3k km. With E2x, you only get 800!

We are good to go. This is going to be a repeat issue I'm told. I'll push for a valve replacement anyway once I'm back in NOIDA!

Mahindra Thar DPF Failure Update 3

Not solved! In fact, I have never accumulated over 8g of soot mass in the DPF ever, checked ten times over 6 months and 15k km.

It was 2g in the morning.
It's 71g now.
I was informed that after 37g only the tech team can step in... Standard regen at the facility isn't an option.

It's stunning how this happened.

The car went straight to level 3 DPF failure - blinking DPF and engine light as well. I had barely driven 70 odd kilometres since I took the car from service earlier today.

I never got a chance to do anything. Got back to the workshop at Leh and they're saying it may take days if DPF spares have to be arranged... Days that I do not have!

P. S: I have not re-fuelled or topped up DEF today. I am still running yesterday's fuel (resulting in only 2g soot after regular hill travel, so I must be doing something right.)

Now the situation seems to have devolved into:

Yet another sensor (DPS?) differential pressure I think - is malfunctioning. This just so happens to be in the immediate vicinity of the DEF valve that had water poured on it - and that the harness itself was 'hot' to the touch, and so will be replaced as an immediate measure. This is the entire engine harness - a fair bit of work.
Then the DPS module *may* be changed.
Finally, since I'm well over the 37g soot threshold, they'll then attempt to revive the DPF by driving around in the third gear.
Finally (pt. #2) the DPF is to be regenerated if we can bring it down to 37g. Else, New DPF. Since this is a failure of upstream exhaust systems, I expect this to be covered in the warranty! Sadly, there is no stock, just amazing.

I wish this were just a DPF issue. This is a failure of a 'rugged model' with poor valves, harnesses, MASS stock management, and just sheer luck!

This just makes me miss my old CRDe. It was bulletproof.

Mahindra Thar DPF Failure Update 4

So as an update I have received exceptional support from Mentokling Motors and from Chandigarh HQ (CSR side.)

There is a persistent DEF dosing valve issue that two more Thars came in with. E21 /22.

This deserves a recall and a permanent fix. Just whacking the valve with a rod is not okay!

I've driven 100 km in the hills now including ascending to 5400m (Khardung La) and without incident. I'm driving low gears with a focus on hitting 60 wherever possible.

As a PSA, the roads beyond Khardung la are washed out for about 25 km. Then it gets brilliant again. Hail the BRO!

Mahinrdra Thar DPF Failure Update 5

Team,

A glimmer of hope!

My Thar has done about 500 km since my visit to the MASS at Leh.
No repeat of the DEF dosing malfunction (which requires a recall IMHO with its high failure rate) which results in the E21+ errors. Long term, this needs a replacement.
Zero DPF issues in my entire ownership barring the DPS-connected engine hardness burning issue that resulted in the self-regen not working!

This includes hours of 1st-2nd gear work. This covers Leh - Nubra - Pangong - Leh - Sonamarg (Kashmir)

I've done 17k km in 6 months and the car keeps giving. I am driving a manual and absolutely refrain from keeping below 1500 RPM in the hills. Don't shy away from hitting 2.5-3k rpm depending on how 'tough' the ask from the engine feels.

Meanwhile, whoever gets stuck at Leh, go to Mentokling Motors and ask for Vikram (chief tech), Jigmet (owner / highly technical), and Ravi (the hands-on guy who will do the real fixing) in this order. Please also copy me (gaurav14mehta@gmail.com) for any comms to Mahindra over email - I am trying to get the DEF dosing valve to recall established. I have personally seen 4 cars come in with E22 issues in two days... Or worse. This includes a Scorpio.

Question - Was the DPF light blinking as well? Did you get intermediate stages (REGEN indication etc) and can you please send me the DTC codes when you read them through the OBD tool?

Here's what BHPian Pancham had to say on the matter:

Another 2020 Thar bites the DPF dust.
What a site for an owner who has been waiting for 9 months to get his dream vehicle and planning a Zanskar trip for 2 years!
So our epic trip to reach Leh through Zanskar comes to an end prematurely. Why? Bhpian Slipstream11’s Thar choked up it’s DPF.
We completed the route (Shinkula- Kurgiak- Purne- Padum- Rangdum) but reached Kargil with the DPF sign and Check Engine light on.
After waiting for around a day and half Mahindra RSA sent a flat-bed to Kargil to pick the car up and send it to Leh. Thanks to them for at least arranging the truck.
But the overall experience has left a bitter taste towards BS 6 diesels and Thar in general. We have been planning this trip since 2020 and the Thar could not make it till the end. It’s like the 2020 Thar is not made for these terrain or rugged conditions. Perhaps it’s better to buy a petrol Thar and use it as a mall crawler.
Now the wait begins to get it fixed at Leh. Fingers crossed.