Hey all, New owner of a 2016 Focus 1.5tdci 120 and seems to have a bit of an issue and hoping for some advice!

Seems a little shaky at idle and down on power when pulling away and a bit knocky at low revs.

I had a quick look with a cheap OBD reader and initially I though it was a blocked EGR valve (First pic) but when looking at it a bit closer it seems the EGR actual reading seems to follow commanded very closely, just too far open the whole time.

Anyone seen this before or have any ideas?!

Thanks in advance!

Welcome!

As a first line response, the focus (pun?) is on one parameter which initially appears OK - EGR commanded and actual has a fixed offset, if so it could perhaps be reset (I'm reluctant o do that without further proper diagnostic work as there's no justification yet?)

What about "proper" fault codes (Forscan recommended by all on here?) as standard EOBD readers usually give generic codes?

59 minutes ago, Shearers said:

Welcome!

As a first line response, the focus (pun?) is on one parameter which initially appears OK - EGR commanded and actual has a fixed offset, if so it could perhaps be reset (I'm reluctant o do that without further proper diagnostic work as there's no justification yet?)

What about "proper" fault codes (Forscan recommended by all on here?) as standard EOBD readers usually give generic codes?

Thanks for the reply! I've scanned it with a friend's Topdon a few days ago and it had 2 fault codes showing. 

I've actually ordered the USB OBD for Forscan but not sure when it's arriving! The EGR does seem to be perfectly 'out' which didnt match the sticking I had expected.

I'm unsure about how closely the EGR should follow the demand instructions and that should be kept in mind. If anyone knows, that could be evidence for a reset.

The codes above don't seem to be related to your engine symptom.

Suggest getting the Forscan code reading and starting a diagnostic search from there

17 hours ago, adjy said:

shaky at idle and down on power when pulling away and a bit knocky at low revs

Could that be a cylinder related misfire, injector issue - worth a look in that area if definitely no fuel supply/rail pressure issues as a starting point? Disconnect injectors in turn/leak off test?

12 minutes ago, Shearers said:

I'm unsure about how closely the EGR should follow the demand instructions and that should be kept in mind. If anyone knows, that could be evidence for a reset.

The codes above don't seem to be related to your engine symptom.

Suggest getting the Forscan code reading and starting a diagnostic search from there

Could that be a cylinder related misfire, injector issue - worth a look in that area if definitely no fuel supply/rail pressure issues as a starting point? Disconnect injectors in turn/leak off test?

Thanks, hoping the USB OBD adaptor arrives today so I can take a look at Forscan tomorrow and see what's what. Will scan and update. 

Appreciate your help!

It's arrived today, done a quick scan and the only thing coming up in Forscan is the TPMS which I am aware of (dead batteries!).

Not sure what else to look at in there?!

What cable or dongle are you using ?

vGate VLinker FS USB OBD Adaptor.

Thanks

14 hours ago, unofix said:

What cable or dongle are you using ?

Only thing I have noticed really looking in Forscan other than the EGR error % is Oil Temperature showing at -40 degrees, sensor voltage 5v. Not sure if these have that sensor tho? 

 

I'd look at live data and set up a screen for the PCM including everything that may be relevant:

Battery Volts, RPM (desired/actual)air temp, intake air temp, coolant temp, MAP, Fuel rail pressure (actual/desired), turbo vane position, DPF  pressure differential, soot loading (open/closed), DPF distances, mass airflow, baometric pressure, boost pressure, total distance, your EGR parameter (demand/actual)

This (and others as required) to be taken at idle and 3000rev/min as a datum point and see what is going on.

If nothing obvious (I'm suspecting misfire somewhere which the above won't determine but test the basics first)

Know nothing about oil temperature as I don't have it but any dodgy sensor can have effect so need to disconnect it to see what that does and if the value doesn't change there may be a wiring fault???

If high mileage then injector leak off test and/or disconnect each in turn first  (when was fuel filter last changed etc?) as said above...

On 5/26/2025 at 12:24 PM, Shearers said:

I'd look at live data and set up a screen for the PCM including everything that may be relevant:

Battery Volts, RPM (desired/actual)air temp, intake air temp, coolant temp, MAP, Fuel rail pressure (actual/desired), turbo vane position, DPF  pressure differential, soot loading (open/closed), DPF distances, mass airflow, baometric pressure, boost pressure, total distance, your EGR parameter (demand/actual)

This (and others as required) to be taken at idle and 3000rev/min as a datum point and see what is going on.

If nothing obvious (I'm suspecting misfire somewhere which the above won't determine but test the basics first)

Know nothing about oil temperature as I don't have it but any dodgy sensor can have effect so need to disconnect it to see what that does and if the value doesn't change there may be a wiring fault???

If high mileage then injector leak off test and/or disconnect each in turn first  (when was fuel filter last changed etc?) as said above...

I haven't had a chance to map this with Forscan (bit of a pain needing a laptop to do it - can't get the android version working)

When I was looking at Forscan I did notice injection correction values looked a bit out. 

Mapped these live in Carscanner app through my phone today.

Looks to me like the injection timing is all over the place as is the cylinder balance (which I think is the same as I was seeing in Forscan but named slightly differently)

Sorry, I can't really make much sense of your graphs, personally, I need any fault codes and live data numbers from multiple relevant parameters to try and make any sense of this (long distance diagnosis isn't easy).

I see the RPM is all over the place (!) and that, IMHO is confusing the issue, I'd use Off, Idle and 3000 RPM as starting points with data for each.

I don't know about the Forscan Android app as I use a laptop, but suggest that needs sorting (anyone or via the Forscan forum?) as it should give Ford specific codes/information that most on here rate and can suggest how to proceed.

Otherwise I am back to guessing which I'm not happy with?

On 5/28/2025 at 7:00 PM, Shearers said:

Sorry, I can't really make much sense of your graphs, personally, I need any fault codes and live data numbers from multiple relevant parameters to try and make any sense of this (long distance diagnosis isn't easy).

I see the RPM is all over the place (!) and that, IMHO is confusing the issue, I'd use Off, Idle and 3000 RPM as starting points with data for each.

I don't know about the Forscan Android app as I use a laptop, but suggest that needs sorting (anyone or via the Forscan forum?) as it should give Ford specific codes/information that most on here rate and can suggest how to proceed.

Otherwise I am back to guessing which I'm not happy with?

Absolutely agree, I'll get some time over the weekend and sort that. Endless errors with unable to initialise application when trying on my phone frustratingly.

Really appreciate your input.

I did manage to get a video of the 'knocking' this morning tho.

Can't upload it here but it's linked below.

https://streamable.com/xgha80

I can hear a bit of rumbling but can't make any judgement on it.

hopefully, you can get the phone app sorted to star to get some real data.

Will wait to hear it...

2 minutes ago, Shearers said:

I can hear a bit of rumbling but can't make any judgement on it.

hopefully, you can get the phone app sorted to star to get some real data.

Will wait to hear it...

Yeh, it's the ticking which you hear a few of as the revs drop too, sounds louder in the cabin than on the video, hard to pick it up but it's pretty noticeable.

On 5/30/2025 at 7:09 PM, Shearers said:

I can hear a bit of rumbling but can't make any judgement on it.

hopefully, you can get the phone app sorted to star to get some real data.

Will wait to hear it...

Finally got it working on Android!

I'm seeing very high MAF commanded but very low measured but not sure what else on there is not as expected?

I've snapped data at idle and 2000rpm, think I got everything you suggested.

I can't see/hear any obvious boost leak, not to say that there isn't anything.

Does anything stand out on there other than the MAF commanded/measured?

Thanks again for your help!

 

1 hour ago, adjy said:

Does anything stand out on there other than the MAF commanded/measured?

Your Actual MAF values look ok to me but the Commanded values look way to high. I don't understand why though.

40 minutes ago, Tizer said:

Your Actual MAF values look ok to me but the Commanded values look way to high. I don't understand why though.

Yeh I just don't understand that at all, or what's triggering it. The measured MAF never seems to get above 80ish on a drive but commanded is off the scale! Also doesn't look like it's triggered a DPF Regen for 900km but still thinks soot loading is 0?!

24 minutes ago, adjy said:

Yeh I just don't understand that at all, or what's triggering it. The measured MAF never seems to get above 80ish on a drive but commanded is off the scale! Also doesn't look like it's triggered a DPF Regen for 900km but still thinks soot loading is 0?!

Maybe it's your Adaptor or a FORScan problem or someone has remapped it or a PCM problem but it is physically impossible for a 1.5 Litre engine to suck in 50g/s of air at Idle speed unless the Turbo was Boosting heavily which it doesn't do at Idle and it would show as a high MAP value.

It might be a good idea to clear the Cache from FORScan and start afresh with the PID's that look wrong.

I did try the relearn maf adaptation on Forscan after this, it commanded lower for a few seconds, then ramped straight back up.

Not aware of any remap but there is always the potential, but something is off!

Very frustrating!

I'll try and repeat the same with my laptop tomorrow, but the measured values I see align with what I was seeing on Windows. 

You could try running the car with the MAF disconnected to see if it runs better using the Default Values in the PCM. 

It will throw a Fault Code but I don't think it will go into Limp Mode.

I've tried with the MAF disconnected, still commanded high but fixed at 4.4 measured - knocking just got louder. Pretty sure it's fuelling based on the wrong airflow which is messing up the injection timing or something?

Appreciate the suggestions!

What about disconnecting each injector in turn to see if it's a general misfire or cylinder related as you seem to be moving away from the actual problem towards a focus on overall engine parameters (and I know I suggested that, Oh the irony!) It should cause a code and you would see if problem changes - it's changing something that is needed?

Non-specific comments:
I didn't know MAF could be commanded but it does seem like a logical thing to demand as the fuel required to react with it could then be decided.
Agree the actual and demand values are out of kilter but if this is at no load which is correct? (I get 77g/s at 3000 Rev/min no load, 2.0l so your actual seems low and demanded high based on the ratio of engine size and speed?)
No differential pressure reading at 2000 Rev/min? (1st & 3rd are same PIDs and 2nd is the only one with an engine speed hence my confusion?)
EGR temp not showing?
Is engine oil temperature MINUS 40 degrees?
Turbo inlet pressure 0?