We have a 2006 Ford Focus Zetec 1.8 TDCi Climate Pack. After picking it up from the garage we bought it from, we noticed that there would be a loss of power when driving, mainly in 1st or 2nd gear. It has happened when pulling from a junction in 1st, and also when going uphill in 2nd. When the loss of power happens, if you take it out of gear and then put it back in, it seems ok. Although today, my wife was driving and she had to pull over, and leave it in idle, for a minute or so. There are no warning lights, and the engine doesn't cut out. We took it back to the garage we bought it from, and they had a look(as it is under warranty), and hooked it up to the diagnostic machine. No codes came up, and the guy who did the test said that it was one of the best engines he had seen, as all the readings etc were near perfect. The only thing that fluctuated a very tiny amount, was something to do with the air flow(?), but he said it should clear itself in a week or so. The garage told us to take the car away, and see how it goes, and if it played up to bring it back(we picked it up yesterday morning(Tuesday)), and since then it has happened again 4 times. When driving along the dual carriageway it has been fine, and the acceleration has been fine aswell. It only seems to be in the lower gears(1st and 2nd). Does anybody has any idea what it could be?
We have now had the fuel filter replaced, and the garage have said that there was an 'o' ring in there that was perished, and they think it could've been causing the problem. The car has now started doing the same thing again. I have been told by a mechanic friend that it could be the EGR valve getting stuck, and to have it cleaned out. Is it better to get it cleaned or replaced?
Since then the car is still doing the same thing. Have now had the Mass Air Flow Sensor replaced, and also the guy at the garage sprayed some EGR cleaner into the air intake while he was changing the MAF. That was about 2 weeks ago, and it is still playing up. Have spoken to a couple of people in work, and they have suggested a couple of things. EGR valve has been mentioned again. Another person said it had happened to him on a focus he had repaired, and he said he eventually traced it to some sort of sensor or switch under the accelerator pedal. Could this be the cause of the problem? Apart from this the car is a lovely car, I even took it up the motorway the weekend, and it was fine. Like I said before, it doesn't happen all the time, and there are no warning lights at all.
We now have another problem happen, when accelerating the car is ok in 1st and 2nd although it still does loss of power thing(going to garage on Monday), but when you accelerate in 3rd and the turbo seems to kick in, there is a sound similar to an exhaust blowing? - Could this be a hose blown, as there is no smoke.
Car is now at garage, and they have said that the clutch is burnt out, and they have replaced it. Could this be the cause of the original problem, or could it still be the EGR valve etc, as it is now getting dirty with the garage, and we are asking for our money back - we have had the car for 2 and a half months, and the warranty expires after 3 months.