Hi, apologies if this has been asked before (sorry, I'm new to the Group) but I have a (2006) Mk 2 Ford Focus 1.8 TDCi but I cannot work out where the problem is being generated.  My Wife's Car - used mainly for shopping runs and getting to/from a local workplace.  Start the car, all warning lights extinguish as they should, but then as the accelerator is pressed to increase road speed speed the red MIL light comes on (the red cog-wheel with the exclamation mark within).  There's no real drop in power (so it’s not in "Limp-home" mode).  I used FORScan and there's (2) fault codes present - P0489 which refers to "EGR Control Circuit Low", and P2263 which refers to "Turbo Boost System Performance" but they both have a identical Additional Fault Symptom - "Signal is above Maximum threshold".  I can turn the car off and then back on again and the MIL goes out, until next time.  If the car is driven gently, the MIL will not make an appearance, but if you have a gradient to climb, and more accelerator pedal is depressed the red light comes on every time.

 

So, I've checked the Turbo Vane Actuator mechanism (Electronic, not vacuum) - that seems to move; I've taken the circlip off the servo actuator linkage to the variable vane lever and the link arm moves freely, so the vanes are not stuck.  Put the link back on (replace the circlip) and revving the car up at idle, the actuator arm doesn't seem to move very much, is it supposed to??? It does go through its full cycle when the ignition is switched off/on/when the engine is started so I don't expect it's going to be a problem with the servo actuator.  

 

I've also checked the EGR mechanism - the rod moves freely in and out within in the cam slots, I've taken off the black plastic end piece, and checked the potentiometer (PCM feedback system) 6k ohms resistance and the variable sweeper arm registers as it should as the quadrant rotates.  I was going to fit a EGR Blanking Plate, so I took out the 2x screws only to find it's already been fitted with one (and one without the hole in too) so although the EGR rod rotates freely, and in/out of the EGR body, it's movement is negated by the use of a blanking plate.

 

So where do I go from here, do I check the MAP sensor and MAF.  I don't expect there's a fault with the accelerator potentiometer as this would induce a different fault code.  I'm thinking of perhaps a blocked Catalyst (which I'm going to remove any way for a clean/replace as she only does short runs).  Is there any way of checking the MAP sensor output voltage, if so - what should it read...

I'm really now beginning to run out of ideas...  The car won't pass an MoT Test with the MIL light on, especially during the smoke test...

 

Happy to hear your thoughts, the two fault codes on the FORScan Tool appear to be linked, they'll both seem to relate to each other, but both actuators appear to be working (even if the EGR is blanked off). 

"The car won't pass an MoT Test with the MIL light on, especially during the smoke test...",   they are not allowed to fail a 2006 diesel just for MIL being on. That only applied to Diesels from some point in 2008 (July I think but not sure without checking). Some MOT testers need to have this pointed out to them. It's clear in the MOT rules.

But I can't advise you on your real queries.