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Just thinking out loud here... Perhaps a faulty sensor (so it really isn't 100% full), or the injectors are supposed to add a little fuel during the exhaust stroke (which is the regen cycle) so the fuel exits the combustion chamber and flows downstream into the DPF where it burns off the deposits. So perhaps this isn't happening. Or maybe it's happening but not injecting enough fuel or not long enough to raise the temperature in the DPF to burn off the deposits... Maybe it has to do with software?
 
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