DPF Won't Regenerate? Check Your Exhaust Sensors First

Had a similar issue with my 2011 Chevy Silverado diesel. As someone with moderate experience working on diesels, I can relate to those DPF headaches. My exhaust back pressure sensor failed last year, causing similar symptoms, warning lights, failed regeneration attempts, and visible smoke. Vehicle diagnostics pointed straight to the sensor. The emission control system basically couldn't properly monitor the exhaust flow. Got it fixed at a workshop, total repair was 245 for parts and labor. The mechanic confirmed the sensor was completely shot, which was messing with the entire exhaust system readings. Before spending money though, what specific warning lights are you seeing? Also, when's the last time you had a full engine performance scan? The exhaust system in these Chevys can throw similar symptoms for different issues. Could you share: Current mileage, Any other warning lights/codes, Recent maintenance history, Type of driving (city/highway split) Let me know these details and I can share more specific insights from my experience.

Thanks for the detailed response. Just did a fresh diagnostic scan at 86343 KM. Getting P2463 and P242F codes consistently. The DPF light started flashing about a week ago during normal highway driving. The pressure sensor readings are all over the place according to the scan tool. Auto repair shop did a basic maintenance service last month, fresh oil, filters, and general inspection. Everything else seemed fine until these DPF and sensor issues started. Getting that sooty exhaust smoke mostly during acceleration, which matches your experience with the bad sensor. Hoping it's just the pressure sensor and not a bigger emission control system problem. The repair cost you mentioned sounds reasonable, definitely better than a full DPF replacement. Planning to get it checked this week. Will get the exhaust back pressure sensor tested first before diving into more extensive repairs. Just wanted to confirm I'm on the right track with the diagnosis.

Yeah, those codes definitely point to the same exhaust back pressure sensor issue I dealt with. After seeing your scan results and symptoms, it's almost identical to what I experienced with my Silverado, especially those erratic pressure readings. When my sensor went bad, the vehicle diagnostics showed similar P2463/P242F combinations. The sooty exhaust during acceleration is a classic sign of the emission control system not getting accurate pressure readings. Really messes with the DPF regeneration timing. Quick tip from my repair experience, have them check the sensor wiring harness too while they're in there. My mechanic found some minor corrosion at the connector that could have eventually caused problems even with a new sensor. The exhaust system takes a beating in that area. The timing matches up too, these sensors typically start acting up around your mileage range. Given your recent maintenance is all good, and the symptoms are so similar to what I dealt with, focusing on the pressure sensor first makes perfect sense. Just make sure they do a complete vehicle diagnostics scan after the sensor replacement to confirm everything's communicating properly. My repair solved both the smoke issue and the regeneration problems completely.

Thanks for the confirmation about the sensor and codes. Those consistent P2463 and P242F readings definitely help narrow things down to the pressure sensor. Your repair experience is really helpful, especially knowing it fixed similar symptoms. Good call about checking the wiring harness during the repair. Car maintenance has been regular, but I hadn't thought about connector corrosion affecting the exhaust sensor readings. Will definitely have them inspect that while they're working on it. Really hoping this fixes both the smoke and regeneration issues like in your case. The vehicle emissions problems started pretty suddenly, which matches what you described. Going to schedule the pressure sensor replacement and testing this week. Will make sure they do that full diagnostic scan afterwards to verify everything's working properly. This is exactly the kind of auto repair feedback I was looking for, real experience with the same problem and a clear fix that worked. Feeling more confident now about the diagnosis and repair approach. The cost estimate helps with planning too.