I've got a focus 1.8 tdci 2006 when one morning it would not start then I called the AA and tried spraying

Some liquid down the EGR inlet pipe and still nothing then he put a blanking plate in the EGR then it started . A new EGR valve is £450 but my friend (ford mechanic) came and had taken the EGR valve apart and it had seized up so the motor on the valve wasn't turning the valve so he was turning the valve manually with long nose pliers very gently which loosened it . So once cleaned he reassembled it took the blanking plate out cleaned the pipes and it started. Fords won't take this apart and clean it they would only fit a new valve costing a lot of money. I hope this helps any one with the same problem

Thanks for the valuable information there Alan!

Unfortunately Ford dont like to do hard work, they like to do the easy and expensive, sell the part, let it be refurbed and sell it on again!

This is old topic but also happened to me with Focus Mk2 1,8 TDCI LYNX.

EGR is clean. Seems my lifting pin gets stuck open, so I cannot start. Need to knock with a hammer to release. When I opened, it can move but really somehow harder from full open position.

There is this solution, to replace lifting pin using replacement part. 

 

I'm not clear if replacing that lifting pin would help, is it maybe worn out ie thinned. But I am not confident enough to try that, no idea how to remove the old one.

Another video for Transit but same EGR, more details here how to put lifting pin.

https://www.youtube.com/watch?v=QUpzpP7_9dM

 

How to open is https://www.fordownersclub.com/forums/topic/89944-how-to-take-off-egr-for-cleaning-in-mk2-18-tdci 

12 minutes ago, ForTim said:

This is old topic but also happened to me

What can be said after 11 years .........

Yes but @Timur has at least added a suggestion to solve the issue?