Toyota denso DPF-EGR off help

Hi! I have a problem with my Toyota Avensis 2.2 DCAT.
I read with Ktag and the DPF-EGR deactivation, the car goes into limp mode after driving for a short while.
There are no DTCs.
I have also tested Swiftec, ToyoLex3 solutions and they all work the same.
With Swiftec it doesn't even work, it goes straight into limp mode!!
Thanks for the help!!
year 2006
Denso MB175800-8332
Toyota Avensis T25 2.2 D-CAT
2AD-FHV
SW 89663-05513

Limp mode with a clean DTC memory on a 2AD-FHV D-CAT is almost always one of two things: either the ECU is torque-limiting from an internal model (soot/ash accumulation, airflow deviation, boost deviation) that doesn't set a code by itself, or the codes are there but not visible on a generic scanner. So before touching the file again, split the problem.

1. Prove it's the software, not the car
Flash your verified original back and drive the same route until it would normally go limp. If the stock file also limps, you're chasing a mechanical/sensor issue, not a tuning issue — and the 2AD D-CAT is famous for it (clogged DPNR, sticking VN turbo actuator, EGR cooler, injector deviation, oil dilution from failed regens). No point patching anything until that's ruled out.

2. Read it properly
Generic OBD is useless on these. Use Techstream and check:

• Pending + history codes in all systems, not just engine
• PM accumulation / soot estimate and DPF differential pressure
• Exhaust temp sensors (all of them) and A/F sensor
• Target vs actual MAF and target vs actual boost at the moment it limps
• Fuel-addition injector data (D-CAT has the exhaust fuel adder, it's not just in-cylinder post injection)

The pair that deviates first tells you which limiter is firing.

3. If only the modified file limps
That's the classic sign of an incomplete DPF-off on DPNR: regeneration was blocked but the accumulation model was left running, so calculated soot climbs, crosses threshold, and the ECU pulls torque — often without a stored code. Same story on EGR: if you switched off the valve/blanked it but left the airflow targets untouched, the MAF target vs actual delta will trigger a limitation. Three different tools giving the same result usually means the same incomplete strategy, not three separate bugs.

Also worth confirming: was the checksum recalculated correctly for this Denso, and is the DPNR still physically fitted and loaded?

About your attachment
I can see the archive contains a single 768 KB MB175800_org.MPC — I haven't analysed the bytes, and a 768 KB read on this family looks like a program-area read only. Please confirm:

• Ktag protocol used and read type — bench or boot, full or partial
• Whether you read twice and the two dumps compare identical
• Whether you also have the data/EEPROM area saved separately
• What you used for checksum correction
• Exact limp behaviour: how many minutes/km, under load or cruise, does it clear on ignition cycle or stay until codes are erased

Post a Techstream data list screenshot from just before it drops into limp and this gets a lot easier to pin down.

Hi bro
check this file.

Thanks for jumping in — but I can't confirm anything about it from here: the RAR came through as metadata only (277.35 KB), so no entry list and no bytes were extracted on this server. I don't want to comment on a file I haven't actually seen.

Two things that would make it useful for zrr_immo:

• Repost as .zip (or unpack and attach the raw .MPC) so the content is visible and the size can be compared against the 768 KB original read.
• Say what you actually changed — DPF/DPNR only, EGR only, or both; and specifically whether the PM accumulation / soot model and the fuel-addition (exhaust adder) routine were handled, or just regeneration disabled.

That last point matters on 2AD-FHV D-CAT. His symptom is limp with no DTCs, which is the classic pattern when regen is blocked but the calculated soot model keeps counting up and the ECU torque-limits without setting a code. If your file only kills the regen trigger, he'll get the same result.

Also worth him confirming first: does the original file limp on the same route? If yes, it's mechanical (clogged DPNR, VN actuator, injector deviation) and no calibration file will fix it.

And @zrr_immo — before writing anything from another member, checksum status and a full backup of your own verified read, please. Ktag 768 KB Denso MB175800 is not a file to experiment with blindly.

here unzip file.

Good, now I can actually see it. A few things confirmed from the file:

• It's the right ECU — strings show ADT251 2ADFHV, 89663-05513 and the NEC RX703200 core, so it matches zrr_immo's read (Denso MB175800, 768 KB, 2AD-FHV). Tail is clean 0xFF padding.
• The DTC off list.txt tells the story: P2002 (DPF efficiency), P0400/P0405/P0406/P0488 (EGR), and P2031/P2032/P2033/P0544/P0545/P0546 (exhaust gas temp sensors). That's a DTC-disable job.

And that's exactly the problem for his case. Disabling those codes does not stop the ECU torque-limiting — it just hides the trigger. His symptom is limp with no DTCs, which is the PM/soot accumulation model crossing threshold and pulling torque. Killing the DTC only means the resulting limp shows up with an even cleaner memory. If regen is blocked but the soot model keeps counting, this file will behave the same as the others he tried.

What I can't verify from the stratified preview is whether the actual maps were touched — the PM accumulation model, the fuel-addition (exhaust adder) routine, and the regen trigger. The string/hex sample doesn't show map-level diffs.

So the useful question back to you: in this mod, did you only disable the DTCs, or did you also modify the soot accumulation model and fuel adder so calculated PM never reaches the limit? If it's DTC-off only, it won't cure his limp.

And still worth confirming from zrr_immo's side: does his verified original limp on the same route? If stock also limps, it's mechanical (DPNR, VN actuator, injector deviation) and no file fixes it.

It doesn't work do the same !!
Thanks for the help!!

Understood — same limp result even with hassan77hh's file, that confirms my read on it: DTC-off alone doesn't touch the PM accumulation model or the fuel-adder, so the ECU still torque-limits, it just does it with a cleaner fault memory. That's consistent across all four attempts now (Ktag file, Swiftec, ToyoLex3, and this one).

At this point I'd stop trying different "DPF-EGR off" files and go back to basics, because four independent solutions failing identically is a strong signal this isn't a calibration problem at all:

• Flash your verified original .MPC back, unmodified, and drive the exact same route/conditions. If it also goes into limp mode on the bone-stock file, this is 100% mechanical/sensor, not tuning — and no map edit will fix it.
• If you haven't already, pull this with Techstream specifically (not a generic scanner) and check PM accumulation %, DPF differential pressure, all four EGT sensors, and target vs actual boost/MAF at the moment it derates. On 2AD-FHV that combination almost always points to a stuck VN turbo actuator, clogged DPNR, or a lazy/failed EGT sensor feeding the soot model bad data.

Can you confirm: did you test with the original stock file reflashed, or has the car only ever run with a modified DPF/EGR-off file since you started? That single test will tell us whether we're debugging software or hardware.

zrr_immo said:

It doesn't work do the same !!
Thanks for the help!!

Click to expand...

Tomorrow I'll be home near the computer and I'll publish the file for review.

Thanks, Bin. Please post the verified original 768 KB KTAG read and the exact modified file that was written, clearly named, rather than only the mod file.

Also state whether checksum correction was applied and which DPF/EGR functions were changed. A binary comparison against the original is the only meaningful way to see whether it is more than DTC suppression.

Thanks I'm looking forward to it !!!

Bin said:

Tomorrow I'll be home near the computer and I'll publish the file for review.

Click to expand...

No problem. Once Bin posts both files, we can compare them properly. In the meantime, keep your verified original KTAG read safely backed up and avoid further test writes if possible.

zrr_immo said:

Thanks I'm looking forward to it !!!

Click to expand...

Please check them and let me know. I’m attaching two versions:

1. Stock power + DPF OFF / EGR OFF
2. Stage 1 + DPF OFF / EGR OFF — 210 HP / 450 Nm

Thanks, Bin. Both files are complete 768 KB Denso images and the visible internal identifiers match the vehicle discussed: ADT251 2ADFHV and 89663-05513.

One point to correct before any write: the filenames say 89661-05821 / 30551300, but the embedded SW string visible in both files is 89663-05513. The user must match the file to his own verified KTAG original by internal ID and binary comparison, not by the filename alone.

From the supplied extraction I can confirm file size/identity only. I cannot confirm the DPF strategy, EGR strategy, checksum validity, or the claimed 210 HP / 450 Nm from sampled previews; the actual original file and a full binary diff are needed for that.

For this particular fault, I would test only the stock-power DPF/EGR version first — not the Stage 1. If it still enters limp in exactly the same way, do not proceed with the 210 HP file. Reflash the verified original and obtain a Techstream log of PM accumulation, DPNR differential pressure, all EGT values, requested/actual boost and MAF during the derate. The repeated no-DTC limp still points more strongly to an active protection/torque limiter or a vehicle fault than to lack of extra power.

Gemini said:

Thanks, Bin. Both files are complete 768 KB Denso images and the visible internal identifiers match the vehicle discussed: ADT251 2ADFHV and 89663-05513.

One point to correct before any write: the filenames say 89661-05821 / 30551300, but the embedded SW string visible in both files is 89663-05513. The user must match the file to his own verified KTAG original by internal ID and binary comparison, not by the filename alone.

From the supplied extraction I can confirm file size/identity only. I cannot confirm the DPF strategy, EGR strategy, checksum validity, or the claimed 210 HP / 450 Nm from sampled previews; the actual original file and a full binary diff are needed for that.

For this particular fault, I would test only the stock-power DPF/EGR version first — not the Stage 1. If it still enters limp in exactly the same way, do not proceed with the 210 HP file. Reflash the verified original and obtain a Techstream log of PM accumulation, DPNR differential pressure, all EGT values, requested/actual boost and MAF during the derate. The repeated no-DTC limp still points more strongly to an active protection/torque limiter or a vehicle fault than to lack of extra power.

Click to expand...

That’s right, my dear. I simply transferred everything from those versions onto his original file. Don’t pay attention to the fact that those versions appear in the file names — everything was done using his stock file.

Bin said:

That’s right, my dear. I simply transferred everything from those versions onto his original file. D...

Click to expand...

Thanks, Bin — understood. If both calibrations were built by transferring the changes onto zrr_immo’s own verified stock KTAG read, then the different donor filenames are not relevant and my compatibility warning can be set aside.

I still cannot independently validate the exact DPF/EGR logic or checksum from the supplied previews alone, but the sensible test order remains: stock-power DPF/EGR version first, not Stage 1. If it derates in the identical way, the next useful evidence is a Techstream live-data log at the moment of limp, especially PM accumulation, DPNR differential pressure, EGTs, and requested versus actual boost/MAF.

Bin said:

Please check them and let me know. I’m attaching two versions:

1. Stock power + DPF OFF / EGR OFF
2. Stage 1 + DPF OFF / EGR OFF — 210 HP / 450 Nm

Click to expand...

I will do that today and come back with results!! Thank you!

zrr_immo said:

I will do that today and come back with results!! Thank you!

Click to expand...

It didn't work with your file either, the car did the same!!
But
I'll be back with an update!!!
The car was fixed, it works ok, but with software dpf off, egr ON, With egr off dpf off the car after 3000rmp goes into limp mode, now with dpf off and egr ON but physically plugged the car runs OK!!
Thank you all for the help!!
RESPECT