EGR/DPF problems?

[Snap63]

• Bought my 2nd Ford diesel (Titanium ECOnetic 1.6 Fiesta, 2014 mk 7.5) 3 months ago from a very reputable dealership. Previous diesel was 1.4TDCi climate, 2008.  Have had 10 previous cars since the 80's, all petrol though.         Liked the Fiesta diesel as used for frequent long trips between March & November.      27k on the clock, first 2 months had worry-free motoring with great mpg.  

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• ·         BUT  In mid-October, 10 days after the last long trip, the fan was running for 4 minutes after ignition off. Never did this when it was hotter weather & nearer 20C ambient temp. Rang dealership, was told it was DPF regeneration & “not to worry”. Was travelling 100 miles that night, but noticed the journey had much reduced mpg by over 22%.from frequent trips before...mpg stayed much lower until had returned, then picked up again.  Rang dealership on return, no appointment available for 2 weeks...so took car back early November.         

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• Left car for 3 hours, was told that the EGR valve had frozen open, "see how it goes".  Was apprehensive coz warranty expired in 2 days...   but assured the "error codes" had been deleted.     Assumed the valve had been cleaned as it had been indicated via error code.   

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• Drove another long trip (over 200 miles, mainly motorway) 3 days later.  First leg fine, as normal, second leg on return showing reducing mpg again - perfect conditions & rpm over 2k most of the way. 

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• Next morning did short journey (2.5 miles) & fan started running after ignition off. Did the same with fan overrunning for 3 days (all short journeys).  Mpg plummeted.  If it were DPF regeneration, I had just done a long trip the day before this started!  Only reason I could think was EGR stuck open again - sending more particles through the DPF, even on a perfect regeneration trip. Rang dealership, but next appointment was in 2 days...

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• Mpg now over 30% down but fan had stopped running after ignition off.  This time was told "fan should run after short journeys anyway" & “it uses more fuel in cold weather!!” (what doesn’t? lol)  & "we never physically looked at the EGR valve, just cleared the error codes & did 5 updates on the software".  Been asked to monitor all dashboard readings . As far as I could, I had already done so! Have fuel receipts & mileage details.  ECU didn't even register the last regeneration date after these updates the week before.  Mpg down from 67 (normal) to 41 at worst (4 days ago).

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• No error codes at all now - but obviously SOMETHING IS WRONG – most likely the EGR valve?  Should I get an independent report of the actual physical mechanics, & not rely just on laptop readings as the dealership do?

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• Since I went there a few days ago, there has been no fan overrunning at all & mpg is slowly climbing again, but still 15% down from normal.   Dealership did nothing except check laptop ECU readings. Think the EGR valve may be sticky in colder weather, but I'm not a mechanic…        Now waiting for next faulty cycle, in the meantime not good for my peace of mind. I have heart trouble myself & I am also primary carer for someone who relies on this transport in an emergency.      I’m definitely not a mechanic but I have a brain to try & understand…    very disappointed after paying full screen price for a 2014 Ford from a Ford Dealership I trusted.  Ford UK take note please! (apparently this version unavailable in US). 

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