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Cleaned my throttle body,egr and maf sensor.Small improvement in cold start sputtering but far from a fix.There is something else going on with these cars.Mine has 36,000 miles on it.Has been doing this since about the time I got the latest nox sensor/reprogram done.
 

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Niebs6.2---You quoted " I was pleased with the improvement in performance, but the car was still bucking, mostly first thing in the morning. " My car was doing the same even after cleaning the MAF,EGR and throttle body.Dealer finally figured out with the help from GM that the intake valves were caked with carbon.The fix is to remove the head and clean/recondition it along with cleaning the intake manifold (that part i'm assuming but the head is for sure).Mine was doing exactly what you describe,first morning start,stumbling and missing,worst when you first put it in reverse or drive and sit there with the brakes on.Fuel mileage was slowly getting worse,stumbling etc. goes away when engine warms up and runs smooth.No check engine light but dealer said they logged multiple misfire codes with their scanner,i guess those codes are stored but no check engine light.My cheap code scanner did not show anything.
 

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GM has some kind of system where they spray cleaner into the intake,let it sit for a couple hours then put some stuff in the gas tank.Not sure if thats just for gas engines though.I'd be scared to hydrolock the engine doing that.They say if no improvement do it a second time.Sounds like a bandaid or for lightly carboned engines at best.My dealership went straight for removal of the head,not sure if the put a scope in the intake before coming up with removing and cleaning.GM may have suggested removal right off.I may get it back this week and i'll try and find out the cost.I see you have about 60K miles,80% highway driving.I have 40K miles,mostly city.Do you live in a cold climate area like I do (Winnipeg,Canada)?
I'd like to know what that 2nd emission reflash actually entailed.
 

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BG Diesel Induction servi
A dealer near me sells BG Diesel Induction service that says to:
  • Cleans EGR valve and passages
  • Cleans plenum and air intake
It sounds promising but I'm afraid that the car is running fine now and I don't want to cause problems.
That BG system is like the one GM uses.They don't specifically say intake valves,makes me wonder how effective it is.In my case GM said r and r the head,no mention of using this method.
 

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Update----Dealer called to say car was fixed.Picked it up and had check engine light immediately.Wheeled back in and told service advisor.He quizzed the mechanics and they said,oh yeah,one of the glow plugs is defective,its on order and will call you when its in.Due to warm weather its ok to drive.With that went on my way for a short highway drive.Pulled into the condo parking spot and pulled the engine cover to see if they broke off the glow plug,was greeted by a hissing sound coming from the injector area.Closer inspection revealed fuel leaking out and bubbling in the fuel injector well in the head.Back to the dealer,checked by them and confirmed,no driving due to safety hazard.Will have to order a new one.The saga continues.In addition I asked the advisor what the cost was so far.He said the cost he has is lower than what someone would pay out of pocket.Dealers cost $2400.00,he said at least $3500.00 for a regular customer.
 

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They charged you $2400??
No its all warranty work.That number is what the dealership charges back to GM for the work,for parts and labor.As I said the advisor said if a person had to do this not under warranty it would have cost them around $3500.00.So it seems that due to EGR mixed with PCV gasses and city driving is death to these cars.Not to mention most diesel fuel that has low cetane and no Top Tier cleaners. Its too bad,when I bought it what won me over was the engine,torquey,felt like driving a big V8,nice quiet ride,felt like a much bigger car.It looks like this diesel isn't the only one with carbon problems,lots of GDI gas engines with this problem.Some have gone to dual injection systems to try and stop the issue,Toyota for one.
 

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That brings up an interesting question: how have diesel engines dealt with this all along? GDI is new, but diesels have always been DI ; how have they avoided carbon buildup on the valves?

Sorry if that's rhetorical, but maybe there's something to borrow for the gas engines.

Doug

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There are past diesels that have carbon problems,mercedes comes to mind and I think some Volkswagens and maybe others.Emissions equipment,bad engineering,fuel that hasn't kept up with these issues.They are now getting into top tier diesel fuel like they did with gasoline.Gas engines were carboning the valves even with port fuel injection due to lack of cleaners in the fuel.Time for oil companies to step up and give the U.S. and Canada higher quality Ie: higher cetane and top tier diesel countrywide.
 

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That first picture should be enough to convince anyone to get rid of the egr.Brutal,you should send that picture to Chevrolet,not that they will do anything.BTW,how does it run when you first start it after sitting overnite and put it in gear? Does it stumble and miss?
 
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