Engine Systems Fault 2006 Diesel Focus Titanium, Please Help...

[PabloPaul]

Hi everyone I'm new to the forums and was hoping I could gleen a bit of your help and experience. I bought a 1.8 diesel titanium focus (06 plate) around 12 months ago. A couple of months back an intermittent `engine systems fault` notice has popped up, this used to happen occasionally on the following conditions (I will try and be as clear as possible) and used to go off on turning the engine off:

Conditions that used to lead to the warning:

COming up to a junction/ roundabout etc, when moving off say in 2nd gear when ideally I should have been in 1st gear for example the car would give a tiny `judder` then instantly get in line with the selected gear but the light would come on, felt like it came on on very rare occasions when I never quite matched the revs to what was needed if that makes sense?

The worrying thing is, the last 2 days the light is on all the time, as soon as I start the car. Feels like I have maybe lost a bit of power (accelleration isn't as fast etc) or it may be that I am scared of damaging something so holding back on the pedal, either way, this warning light is on permanent now and I am panic stricken in case the damn thing breaks down (no spare money/ need the car for work, usual stress)

So, does anyone have any ideas what it might be? Is this a known issue so I could try A, B or C before taking it to a garage for diagnostics and possible repair (none of which I can afford lol)

Thanks in advance for any advice guys, I have taken a pic of the offending light and posting it here:

[APJ]

Mine had a similar issues a few years back. It turned out to be the EGR valve, which needed replacing. Wasnt opening/closing properly which meant the revs at idle would hardly be enough for the engine to run. The EGR valve can become clogged over the years...if your quite confident with taking bits off your car this part can be removed and cleaned, but is a bi*ch to get to on the 2.0tdci. May be slightly different location on a 1.8 and therefore easyer to get to. I just got mine replaced in the end by ford..car was perfect after that:-)

[PabloPaul]

Oh wow thank you for teh quick reply, can you help me with what an EGR valve is and how much it costs to have it replaced? Or how much the part is to do it myself?

And also, what would happen if said part didn't get replaced? I'm guessing knackered engine right?

[APJ]

EGR just stands for 'Exhaust gas recirculation'. It works by recirculating a portion of an engine's exhaust gas back to the engine cylinders. The part new is about £120-£150 roughly. Cant rember what ford charged me for new part plus fitting, will check when i get home if can find paper work!

If you dont get it replaced then it will gradually get worse until the car wont even start. But mine took several weeks for this to happen. Didnt do any lasting damage to the engine.

The symptoms you've described could be any number of things really but EGR might be a good place to start mate

[PabloPaul]

Ok thank you, does anyone have a diagram/ photo of exactly where on the 2006 diesel focus this part is located?

[APJ]

almost anything on a Focus can cause an engine system fault! Could even be something as simple as ya battery is on its last legs. How many miles has your Focus done?

I might have a pic of the location of EGR in my engine bay...will see if can find it

[APJ]

[APJ]

[PabloPaul]

Thanks for the help mate, sorry should have said the battery is only a few months old, I bought a new one around April. Car had a Ford official service around July this year as well and never had problems with it other than this.

Car has done around 93k miles and has full service history, we bought it around 79k miles

[APJ]

ok so can rule battery out, thats good

Yours is at at that age where things like EGR and DPF start failing. I bought mine with 88k on the clock and the EGR failed before i got to 100k. Had also had full service history. But touch wood other than the EGR i havent really had any issues...obviously i got the CAM belt and water pump changed as soon i got the car.....but its up to 136k now. Only problem ive got at the moment is the heat shield under the car has come loose at the back end...and may need new exhaust in the near future as still has the original on

I think the life of the EGR can depend on how the car has been driven. When i bought mine it had mostly been used for school run and a very short commute. So no wonder the EGR was clogged up!

[PabloPaul]

Hi thanks again for the helpful replies, my engine doesn't look `quite` like yours. I have taken some pics does anyone know where on my engone the EGR valve is please? Or is it not on any of the pictures I have taken?

[Hippo]

You could try blocking the egr with a blanking plate. Costs about 4 pounds and worked for me

[APJ]

someone here must be able to locate it in those pics...on mine you could almost not get a hand to it, was right up almost directly under the front window....right at the back of the engine bay

[Stoney871]

Your EGR is the component with the pipes going to/from it in your last picture.

[Stoney871]

APJ mentioned DPF.

You don't need to worry about that as a 1.8 tdci doesn't have one. :)

[PabloPaul]

Thanks again for the help guys but which component in the last picture am I needing to check?

[Hippo]

Part A mate. Your see a flexi pipe going into the back. I believe its 2 8mm bolts.. could be 10mm. Its akward to get your hands in

[PabloPaul]

Oops forgot about this thread, I'm not sure the EGR is to blame now, a mechanic read the fault code and it's a number 4 injector fault of some sort but thanks Gary for the reply and thanks to all who helped with this :)

[smitjjo]

Hi i have a ford focus 2.0 tdci 2005 197000 kilos on the clock there was black smoke coming from the exhuast for a second and then the care loose power after that there was a massage on the pannel saying engine fault and the car come to a stand still.When i open the hood there was a water pipe in front of the termostat housing that come loose and know the car dont want to start.