ford focus egr valve problem?

Ive just had the edr valve trouble with my 2010 tdci c-max engine. On my way home from work last week engine cut out and wouldn't start . AA man towed me to my local garage, and after doing some tests my mechanic found it was the egr valve. He showed me the old one, he said that it had water inside caused by condensation which had blown 2 diodes Ijust wondered if it was a recurring problem.

RICHARD FLINT
March 2014

I have a focus C-max 04 reg 2ltr TDCI and have the same problem
you can clean the EGR valve which is poss dirty, when the valve sticks it looses power like there is no turbo.
when it goes dead stick its called limp mode.
usually to protect the engine, this is poss a condition of the egr valve.
I have ordered a haynes manual for my car and going to try some cleaning of said valve.
if you have it tested on a diagnostic machine it will poss tell you its the sensor or solinoid which on my car is the same part (which is what I have changed to no difference).
you can also aparently use a blanking plate to isolate the egr valve so you dont get the problem this stops some black smoke when you kick down the accelorater
and gives you some extra power too.

Lee Hooley
May 2012

The issue was the accelerator pedal - wear in the plastic parts causing the variable resistors inside to go open circuit- cost me £25 for the computer to be connected and £20 for a newer second hand pedal from the scrappers- all fixed now. Apparently the pedal assembly on the older ones is a common issue.

Mark
December 2010

I have had the same issue, the EGR valve is part of the intake manifold and will need the whole manifold (1999 model TDI). The MAP sensor on the back of the engine bay with the small tube connecting to the intake manifold could also be duff. I intend to visit a scrapyard to get some swappable parts to diagnose at the weekend (car will still get me to work but get the flashing glowplug light occasionally). Think the Map sensor is the cheapest option and will try that first followed by a cleaned up intake manifold. If that doesn't work then maybe time to check for bad wires.

Mark in West Mids
October 2010

I had the same problem no power but the car started ok
I called the RAC guy he tapped the EGR valve on the right hand side with a hammer, problem solved.
He told me the valve was stuck open (soot build up) he said it was common in fords.
He told me it needs cleaning. (not sure how much that will cost)

Tony Spalding
September 2010

Thanks, Nathan (only just picked up your replies - sorry!).

55 reg, so less than five years old, but high mileage (~90k). I stalled it last week (I don't think it cut out, but pulling away from a junction in the wrong gear caused a stall and the engine system fault message came on). Have continued driving, and performance is normal: have done about 1400 miles since the egr diagnosis ...

Keith
April 2010

keith, whats the age of your car? it could be your injectors. Has the car started cutting out yet.

nathan rivers
April 2010

i too had the same problems. black smoke when accelerating hard. Rapid fit and fords could not fix it, so i took the car to colchester fuel injection. This is a common fault aparently and they just blanked it off...
No more smoke and no more egr valve to go wrong.

nathan rivers
April 2010

I don't have an answer, but the same problem: the Ford main dealer solution is now £50 (for the diagnosis, which is done) and £818.61 for the new egr valve. 250 miles further on, and the warning lights have not (yet) reappeared. What should I do?

Keith
March 2010

re above ive been told to unplugg the valve and this may assist. if not like me you connector may have a break in the wire . the answer is not 400 quid but a scrap merchant same car and cut the connector off. then very smll cost to fit to your car. my prob is a small break in the wire.!

brooksy
October 2009

egr valves regulary gum up with soot and normally just need a clean but on odd occasions need replacing.i have just done a 2006 focus with the same problem

neil
August 2009

yes same fault ford main dealer charged 400 pound still not right they did not bother to drive and test it. i think its a electrical conection some where My son a mechanic said this fault will not show up with the diagnostic tester. Do you know the cost of a EGR valve?.
Wendy.

wendy wagstaff
March 2009

We have also the same problen cost us £500.00 still the same fault I have carried out thorough tests and it only happens when engine is hot, leave for half hour or more and it starts ok. I think its an electrical fault due to expansion.

wendy wagstaff
March 2009

Check the EGR harness plug. Mine needed a good WD40ing ang opening and closing (sliding ) for 10 mins. Has cured the engine managment light. EGR valve fine !

Rob SMITH
October 2008

I just read your blog, I having the same problem with my X reg.focus diesel TDi 1.8 ghia, i have just been fleeced by ford dealership for £80, to tell me its the EGR valve and want £500 to replace EGR valve, how did you resolve? im looking all over the web for EGR valve spare part I will fit myself any suggestions?

Mike Porter
October 2008