If your EGR is repeatedly plugging up it is related to poor combustion.
You most likely have one of the issues below:
- extended idling or insufficient operation at temperature (as mentioned already)
- bad EGR valve (Ford updated the EGR valves in 2008 or so)
- old calibration (processor flash update needed)
- poor fuel (may need a cetane additive)
- bad or weak FICM (could be a result of bad electrical system - batteries and/or alternator)
- low fuel pressure (plugged or wrong filters, or weak regulator spring, or weak pump)
- Old or wrong oil (injectors are actuated by high pressure oil)
- possible injector issue
Make sure your batteries are good and strong - load test individually
Make sure your fuel quality is good (check fuel sample and drain the water from the HFCM regularly)
Use only Motorcraft, Racor, or International Fuel and Oil Filters
Use the proper oil and the proper oil change frequency
Check your FICM voltages (lots of posts on the web on this)
Change your EGR valve out instead of just cleaning it
Get the most recent flash update at Ford
A fuel pressure gauge is a NECESSITY IMO. Fuel pressure must be above 45 psig at ALL times. If it isn't the regulator spring will most commonly resolve the low pressure, but sometimes the pump is bad.
Last item on the list would be an injector issue, but you almost always have operational issues w/ even one weak injector.
You most likely have one of the issues below:
- extended idling or insufficient operation at temperature (as mentioned already)
- bad EGR valve (Ford updated the EGR valves in 2008 or so)
- old calibration (processor flash update needed)
- poor fuel (may need a cetane additive)
- bad or weak FICM (could be a result of bad electrical system - batteries and/or alternator)
- low fuel pressure (plugged or wrong filters, or weak regulator spring, or weak pump)
- Old or wrong oil (injectors are actuated by high pressure oil)
- possible injector issue
Make sure your batteries are good and strong - load test individually
Make sure your fuel quality is good (check fuel sample and drain the water from the HFCM regularly)
Use only Motorcraft, Racor, or International Fuel and Oil Filters
Use the proper oil and the proper oil change frequency
Check your FICM voltages (lots of posts on the web on this)
Change your EGR valve out instead of just cleaning it
Get the most recent flash update at Ford
A fuel pressure gauge is a NECESSITY IMO. Fuel pressure must be above 45 psig at ALL times. If it isn't the regulator spring will most commonly resolve the low pressure, but sometimes the pump is bad.
Last item on the list would be an injector issue, but you almost always have operational issues w/ even one weak injector.
