Why is the EGR on our car repeatedly getting blocked?
My son's 2019 Ford Focus 1.5 diesel shows an EGR restricted flow light every 8000 miles. We clear this by dismantling and clearing a metal mesh filter which gets completely blocked with soot. This is located on the metal pipe as it comes out of the exhaust before it goes into the EGR and DPF. Once the filter is cleared it runs for another 8000 and happens again. Rinse and repeat.
Any suggestion what is causing this build up which seems more than the mesh filter is designed to cope with? The engine runs well and does five hour continuous runs on long journeys faultlessly. We have used fuel system and injector cleaners which improve running.
Any suggestion what is causing this build up which seems more than the mesh filter is designed to cope with? The engine runs well and does five hour continuous runs on long journeys faultlessly. We have used fuel system and injector cleaners which improve running.
Asked on 11 April 2025 by Roarke

If this filter is continually getting blocked it suggests that there is excessive soot elsewhere in the system, so it could be that with time and mileage the intake manifold is clogged and this is being passed through before reaching the filter. It is also possible that the EGR valve is not functioning correctly causing an excess of recirculated exhaust gasses. Tracing the cause could be time consuming, but a good starting point would be to check the inlet manifold for a build up of deposits and the EGR valve for damaged wiring, vacuum leaks and solenoid operation.
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