On higher mileage vehicles, one or more EGR orifice in the intake manifold may plug with sludge. This can cause the engine to misfire when first accelerating because too much exhaust gas is directed into the cylinders where the orifice is not plugged. Cleaning the clogged passages should correct this concern.
Car Problem Reports
Ford Freestar EGR Orifice in Intake Manifold May Plug With Sludge and Cause Misfire
Ford Freestar Problem
Average Mileage: 88,370 mi (46,000 mi - 126,000 mi)
Visitor, 2006 Ford Freestar, 126,000 mi
Mis-fires - We get error codes that say cylinder 1 and 3 are misfiring (P0301 and P0303) We also just got code P0352-Ign coil B primary Secondary CKTR - Have not researched that yet.
Visitor, 2004 Ford Freestar, 120,000 mi
My Freestar has been sputtering off and on when I try to accelerate, sometimes stalling out on me. It can go days without doing it, then do it all day long for a few days. So far, we have tried changing the fuel filter, and other things my husband thought it may be. We will be checking the EGR Orifice, seeing if it is plugged up.
Visitor, 2006 Ford Freestar, 46,000 mi
egr valve plugged with sludge , spray fuel injection cleaner , and added lucas gas treatment
Visitor, 2005 Ford Freestar, 85,000 mi
did not pass smog check.
Ford dealer charged 506.00 to replace egr valve
Engine starts but will not idle.