2022 Refresh AT4 1500 Duramax 3.0 Diesel Check Engine Light and Exhaust Leak

What was the outcome?
Im having the same issue on my 2022 Sierra Elevation 3.0 Diesel. Check engine light, app says emissions system problem. Dealership is now waiting on parts (no eta) to fix it. New catalytic converter or something that has to do with the regen cycle. Ohh best part, the torque converter was breaking apart and damaged the valve body in the transmission. Sooo, i get a new transmission at 7800 miles.
 

I have a 2021 High Country, 3.0l turbo diesel. At about 1000 miles, I got the dreaded CEL with a P1488 code. My dealer when thru all the required attempts to fix it; torque the particulate sensor, torque exhaust pipe clamp, add 'Tiger Tape' to the exhaust pipe joint, smoke test for exhaust leaks, replace the flex joint.....all to no avail. I was always skeptical about the exhaust leak theory. After all, how could the truck know there was a small exhaust leak to atmosphere?? In total, my truck was at the dealer service 7 times with no resolution. Each time they reset the code and the CEL always came back on within several hundred miles. I was finally able to get the regional service tech representative involved. He instructed my dealer to replace the whole exhaust system, including the cat convertor. Probably $2-3000 in parts. That has solved the problem.

Apparently there were some manufacturing variances with the exhaust pipe joint aft of the particulate sensor. This allowed a small air leak 'INTO' the pipe between exhaust pulses which confused the emission controls. A small number of exhaust pipes with this slightly defective joint all showed up with this same problem. I also had a particulate sensor that was occasionally sending bad data. This was identified using a data collector on a 10 mile drive.

I've since discussed this issue with an engineer friend who specializes in engine emission certification. He says the very first thing they do in preparing for a test run is pressure test the exhaust system and repair even the smallest leak. Otherwise, they would never get a consistent result. So, this rather implausible solution has some basis in science.

I've put about 10k miles on it since the fix and no CEL. Yea! I commend my dealer for sticking with me on this. They were carefully following the various Tech Bulletins and instructions from Detroit and always accommodated my schedule and provided a loaner car when there weren't many available at the time.
 

Keep in mind that anything you get right now they can use society as a reason for not being able to help you if you should ever need parts. If you comb the internet for each truck you would otherwise go with they all seem to have issues. It’s just a matter of will you win the bet that you don’t have issues with yours. I have a coworker who just bought that 70th anniversary corvette. Someone nailed him from behind with not enough insurance to cover. If he sues he could lose because that person doesn’t have anything. But the parts won’t be manufactured as Chevy told them they only have enough to finish their builds. No extra parts for him. So his 140k car now sits in limbo, his rental ran out and he makes a payment for a car sitting on a lot. All crazy.
I do not agree with this statement they can use economy as an excuse. The lemon law is clear and does not have any exceptions for backorderz
 

I have a 2021 High Country, 3.0l turbo diesel. At about 1000 miles, I got the dreaded CEL with a P1488 code. My dealer when thru all the required attempts to fix it; torque the particulate sensor, torque exhaust pipe clamp, add 'Tiger Tape' to the exhaust pipe joint, smoke test for exhaust leaks, replace the flex joint.....all to no avail. I was always skeptical about the exhaust leak theory. After all, how could the truck know there was a small exhaust leak to atmosphere?? In total, my truck was at the dealer service 7 times with no resolution. Each time they reset the code and the CEL always came back on within several hundred miles. I was finally able to get the regional service tech representative involved. He instructed my dealer to replace the whole exhaust system, including the cat convertor. Probably $2-3000 in parts. That has solved the problem.

Apparently there were some manufacturing variances with the exhaust pipe joint aft of the particulate sensor. This allowed a small air leak 'INTO' the pipe between exhaust pulses which confused the emission controls. A small number of exhaust pipes with this slightly defective joint all showed up with this same problem. I also had a particulate sensor that was occasionally sending bad data. This was identified using a data collector on a 10 mile drive.

I've since discussed this issue with an engineer friend who specializes in engine emission certification. He says the very first thing they do in preparing for a test run is pressure test the exhaust system and repair even the smallest leak. Otherwise, they would never get a consistent result. So, this rather implausible solution has some basis in science.

I've put about 10k miles on it since the fix and no CEL. Yea! I commend my dealer for sticking with me on this. They were carefully following the various Tech Bulletins and instructions from Detroit and always accommodated my schedule and provided a loaner car when there weren't many available at the time.
This is crazy!! My truck has been at the dealer for 5 weeks waiting for an exhaust clamp and from your post it will not even fix it. So far new converter, DEF fuel injector, clamp, Regen, and now another clamp.
 

So I took my truck back into service when the clamp arrived last week. Picked up the truck on Monday afternoon once the clamp issue was resolved. Not even 50 miles later on Tuesday the check engine light and service emissions control text came through again! Got it back into service and the advisor put me in contact with GMC to start a claim. Claim was elevated and I got a call about a preliminary review for a buy back. So dang frustrated. I waited a long time since I ordered it and hope I don't have to wait another 6 months to get a new one.

Has anyone gone through the buy back process? If so let me know what happens from here.
 

Do you have a dealer who is supporting you in the buyback? The process took 3 months from the time we started and we had a fantastic dealer who pushed for us the whole time. We had a regional service rep involved assisting us as well.

The two main things I would consider are: do you have your dealer helping you with the process and is the truck you have/want rare or common? If you have a white or black AT4 it's going to be a lot easier to find a replacement one than a blue one like mine for example.

We dropped the truck off 6/29 for the 6th attempt to fix the issue and started the buyback process at that time. We did not have the vehicle again - meaning it was at the dealership from the start until the finalization of the buyback. Consider how you will get around - have you asked about a loaner / rental? Will they let you keep your truck during part of the process? The timeframe can vary based on what I have seen on forums and ours at 90 days seems like it was on the shorter end of the spectrum so be prepared.

The crazy part was our new replacement truck had the same issue at about 1600 miles. We took it in. There's a tech bulletin about it now I'm sure you've seen ( https://gm-techlink.com/?p=16839 ). Leak was found at the clamp where most are being found in the exhaust near that flex joint underneath (fig 4 in that tech link). GM dictated the exhaust tape fix. So far it's been about a week and no CEL. Fingers crossed.

They know more today about the issue than they did when we started dealing with it back in early May. They might be able to fix yours but I can fully appreciate how frustrating this can be regardless.

I wish you the best whatever you choose.
 

So I took my truck back into service when the clamp arrived last week. Picked up the truck on Monday afternoon once the clamp issue was resolved. Not even 50 miles later on Tuesday the check engine light and service emissions control text came through again! Got it back into service and the advisor put me in contact with GMC to start a claim. Claim was elevated and I got a call about a preliminary review for a buy back. So dang frustrated. I waited a long time since I ordered it and hope I don't have to wait another 6 months to get a new one.

Has anyone gone through the buy back process? If so let me know what happens from here.
Keep us updated on this please. I started a claim and was told by GM best thing is to wait until the truck is fixed and they would try and compensate. I was not happy with this as they could not answer basic questions like 1. When will the truck be fixed? 2. What compensation? Pretty basic questions in my opinion.
 

Keep us updated on this please. I started a claim and was told by GM best thing is to wait until the truck is fixed and they would try and compensate. I was not happy with this as they could not answer basic questions like 1. When will the truck be fixed? 2. What compensation? Pretty basic questions in my opinion.
Any update?
 

Check engine light came on again today. Same code P2C7A. Keep in mind this is the second truck - after we did a buyback on the first one. So far the new truck has been in, exhaust leak, tape fix. Now has to go back for whatever comes next.
 

Check engine light came on again today. Same code P2C7A. Keep in mind this is the second truck - after we did a buyback on the first one. So far the new truck has been in, exhaust leak, tape fix. Now has to go back for whatever comes next.
So the issue will be long and drawn out it seems. The new truck having the issue is a little surprising. When did you purchase the first truck and get the second truck?
 

First truck was bought in May. It started within 300 miles about a week in.

The new truck was built in August and we took delivery in Late September
 

First truck was bought in May. It started within 300 miles about a week in.

The new truck was built in August and we took delivery in Late September
Thank you. My truck was also built in May. Was the buy back process difficult?
 

I posted a bit about it earlier in the thread but for me it was about 3 months waiting to get all the things lined up to get it finished.
 

I posted a bit about it earlier in the thread but for me it was about 3 months waiting to get all the things lined up to get it finished.
Thank you for the response. That’s longer than I thought it would take. This process has been frustrating for me. This is week 6 without my truck
 

Back
Top