Focus Mk2 TDCi intermittent 'Engine systems fault'

ChrisD. · 13 Jun 2016 at 14:28

I've had this problem for ages but I've never had it looked at except to read the code which was EGR valve.

One of two things happen, sometimes both at the same time.

1) I will have literally no power pulling away at a junction. I have to give it a load of rev's and it will eventually go. Pretty annoying and dangerous at times especially when the thing stalls pulling onto a busy roundabout. Combined with this I sometimes get no power and the car will kangaroo violently. This happens more at speed, ie doing 30mph at 2k rpm then changing gear or whatever.

2) Engine systems fault comes up on the display. It stays up till I turn off the ignition off then on again. Sometimes it comes up and the car drives fine, other times it drives like issue 1 above.

It's the 1.8 diesel engine with about 40 bhp. I think it's actually around 100. No other issues, mpg is between 55 and 60, no excessive smoke, no power issues otherwise (except the lack of it).

Not really sure I want to pay dealer prices but equally I don't want to get robbed by an indy that doesn't know what they're doing.

Are these engines renowned for it?

snips86x · 13 Jun 2016 at 14:36

Can you hear the turbo on it at all? I remember a similar issue with an old work van, I think it was a pressure release value or something those lines.

Jamesyboyjim · 13 Jun 2016 at 14:39

Get the fuel filter checked / changed. Had this issue myself on a mk3 focus and seen it on other diesels. Sounds like its probably clogged so struggling to pull fuel through.

ChrisD. · 13 Jun 2016 at 14:45

snips86x said:
Can you hear the turbo on it at all? I remember a similar issue with an old work van, I think it was a pressure release value or something those lines.

No, not really but then again I'm used to hearing the turbo on my Evo which is somewhat louder. I'm sure it's working though, there's a distinct surge in power over 2k rpm or so.

Jamesyboyjim said:
Get the fuel filter checked / changed. Had this issue myself on a mk3 focus and seen it on other diesels. Sounds like its probably clogged so struggling to pull fuel through.

Okay, it's not due a service till September but I don't recall seeing anything in the history to suggest the filter has been changed. I've found a Ford 'specialist' in Cheltenham so will probably take it to them for a look.

radderfire · 13 Jun 2016 at 14:46

I have a 2005 Mk 2 Focus 2.0 TDCi, and had similar symptoms. A new EGR valve was required (£300 ish serviced by a Ford dealer, this was a few years ago). I got it changed straight away because it did not feel safe driving the car like that.

I believe it is a reasonably common issue. The valve fails or gets blocked. Here is a related video I found about it on YouTube (not saying you should fix it yourself, but for your interest):

https://www.youtube.com/watch?v=t3RJdrk2Fsg

ChrisD. · 13 Jun 2016 at 14:48

radderfire said:
I have a 2005 Mk 2 Focus 2.0 TDCi, and had similar symptoms. A new EGR valve was required (£300 ish serviced by a Ford dealer, this was a few years ago). I got it changed straight away because it did not feel safe driving the car like that.

I believe it is a reasonably common issue. The valve fails or gets blocked. Here is a related video I found about it on YouTube (not saying you should fix it yourself, but for your interest):

https://www.youtube.com/watch?v=t3RJdrk2Fsg

Yeah, apparently the valve is a pain to get to so it's not cheap to replace.

Jamesyboyjim · 13 Jun 2016 at 16:06

Dooksy said:
Okay, it's not due a service till September but I don't recall seeing anything in the history to suggest the filter has been changed. I've found a Ford 'specialist' in Cheltenham so will probably take it to them for a look.

Filters are supposed to be changed during a service, but I'm told they are quite a cheap part and a bit awkward to do, so garages like to 'forget' to change them. This is what I was told anyway when I got my mk3 focus sorted. I was told it looked like it had never been done. Of course there's a chance that it was filled with some scabby fuel at some point.

Our car was only affected when it was filled up, after a week or so, the car would run perfectly.

ChrisD. · 13 Jun 2016 at 16:37

Jamesyboyjim said:
Filters are supposed to be changed during a service, but I'm told they are quite a cheap part and a bit awkward to do, so garages like to 'forget' to change them. This is what I was told anyway when I got my mk3 focus sorted. I was told it looked like it had never been done. Of course there's a chance that it was filled with some scabby fuel at some point.

Our car was only affected when it was filled up, after a week or so, the car would run perfectly.

Cheers, I don't think there's any correlation. It can be fine for weeks, then I get the issue several times in the same journey. Makes it down right annoying to drive.