If your EGR valve is gummed up, then you have some root cause issues to find.

Incomplete combustion can gum things up and cause EGR valves and turbos to stick.

Bad sensors (like the MAP issue you found) can contribute to poor combustion efficiency. So can bad fuel or weak fuel pressure or a bad FICM. Excessive idling can also cause issues. Sometimes even a bad EGR valve itself can contribute.

Some poeple feel that the ccv system also gums things up. I rerouted mine to a filter on the frame rail and remove a fair amount of oil from it each oil change. It probably doesn't really hurt anything, but it doesn't help either. What is for sure is that oil in the CAC system can soften certain boots (ie the original ones from Ford) and can make it hard for them the seal and saty on. All-in-all, I like my ccv reroute mod.

 

Sark'
I really didnt need to clean the MAP sensor. It was fairly clean because the hose going to it was cut halfway thru at the fitting on the manifold. Also the fitting was almost totally plugged. I replaced the hose and used a drill bit and Brakeleen to clean out the fitting off of the truck. Totally dry before reinstalling. I try to avoid using anything that might be to damaging to the components.

 

Mark,
I believe the MAP sensor was the root cause. Even though it was reading, I believe the reading was lower than actual due to the large cut in the hose at the fitting. I'm sure it happened when the studs were done.
My CAC boots have oil in them also. I am actually on RiffRAff ordering them now. I also read your CCV reroute sticky and I am going that route also. It is definitely on my next mod-list. My FICM will be in the mail to ED on MON AM and I will be installing my MBRP 4" stainless Turbo back exhaust when it arrives.
At this pont I'm considering pulling the turbo and intake to clean them both. Im worried the residue will just plug everything back up again. I have had the EGR cooler and oil cooler replaced about 10K ago and the engine was studded about 7K ago. I didnt have a loss of power until after the studs. When the tech did the studs he checked and cleaned everything and stated the turbo was in good shape then. Is it worth the effort or am I just over concerned?

 

You may want to get everything back together and see how it runs, but reading your posts, it sure sounds ike the turbo vanes are sticking also (even though they weren't when your mechanic did his work).

 

Mark
My Edge Insight CTS shows the VGT cycle from 85% to 15% under full throttle. When I first put my foot in it last night(@normal operating temps) it had terrible hesitation. VGT cycle stayed at 85% and 0 boost until it started going and then the turbo came on like gangbusters. Went straight to 15% and 28 Psi boost. This was just after I completed the work. I cleared the DTC's. Should I have unplugged the battery's to clear any resident memory?
This morning the ambient temp was in the low 50's and the truck accelerated from a standstill better then it ever has. Same #'s, 15% VGT cycle and 28Psi boost. After driving it around 30 miles everything ran great. Checked DTC's just to be sure and I had a P0299. Think that happened yesterday and I just hadnt cleared it.
If the turbo is cycling the full extent (85%-15%) what indication should I see that it is sticking? Slow to respond from a standstill?

 

Sounds like you are good to go. Your VGT readings and boost readings seem to be where they should be.

for a possible sticking turbo - I would see if the P0299 cme back after clearing it.

 

Mark
Do you think since I found the sticky crap in both the EGR, IAT2 and MAP sensor fitting that it would be worth checking the turbo and intake or just wait and see if it re-occurs?

 

I guess it depends on your own circumstances. If you can not afford unplanned down time, then it might be wise to clean it sooner rather than later. If you have another vehicle you could drive if it ever started sticking on you, I guess I would wait. That is just my opinion I am sure others might think differently.