09 Ford Focus estate 1.6 TDCi Zetec 109bhp - Intermittent engine stutter

Honest John Back Room » Technical matters
What is life like with your car? Let us know and win £500 in John Lewis vouchers | No thanks
View Threaded
Sun 7 Apr 2013 14:47
09 Ford Focus estate 1.6 TDCi Zetec 109bhp - Intermittent engine stutter - Papa Lazarou

Hello there, any helpful ideas are gratefully appreciated.

Bought this car just over a year ago, 1 previous company driver, little over 80k at the time with full Ford service history, showing average MPG of just under 50mpg back then.

I managed to get that up to around 52mpg for quite a while, had it seviced (independent garage belonging to a friend) in line with stated schedule (Air filter looked like the one fitted by the factory when it was removed, go Ford dealers) and the mpg improved a little more to around 54mpg.

Shortly after I noticed an intermittent power drop similar to a misfire in a petrol engined car, always under minimal load conditions and around 1700 rpm ( as per the dash ). It comes and goes and isn't really a problem other than a small annoyance but my mpg has dropped considerably since this started happening to it's current level of around 44mpg.

Engine isn't lumpy at any other time, smooth and quiet on tickover and I haven't noticed any excessive smoking either, it passed an MOT yesterday so the emissions must be ok too. Now on 106,000 miles.

My friend is of the opinion that a clean of the EGR valve is the first action but seems reluctant to do it as they are apparently real awkward b*****s to get to. I have been reading some stuff posted on the internet which includes posts here so thought I would ask your thoughts?????

Car has a wet partculate system, I only ever 'fill' the tank and use BP fuel as advised by more than one mechanic, can't speak for the previous driver.

No lights show on the dash so unlikely to show any fault codes if plugged in to a fault reader.

So any advances on EGR valve??????????

Many thanks for reading this and replying if you take the time to.

Regards

Papa.

Edited by Papa Lazarou on 07/04/2013 at 14:48

Reply | Report as offensive | Link
Sun 7 Apr 2013 15:19
09 Ford Focus estate 1.6 TDCi Zetec 109bhp - Intermittent engine stutter - dieselnut

I would agree, most likely a sticking EGR valve. Perhaps you can disconnect the activating vacuum pipe for this easily & see if it cures the problem, although it might bring up the EML.

Reply | Report as offensive | Link
Sun 7 Apr 2013 15:37
09 Ford Focus estate 1.6 TDCi Zetec 109bhp - Intermittent engine stutter - Papa Lazarou

Thanks for replying I will put pressure on my friend to get it at least cleaned, anyone would think I don't pay him enough for his time. ;-D

Reply | Report as offensive | Link
Sat 27 Apr 2013 01:04
09 Ford Focus estate 1.6 TDCi Zetec 109bhp - Intermittent engine stutter - milliecanillie

Thanks for replying I will put pressure on my friend to get it at least cleaned, anyone would think I don't pay him enough for his time. ;-D

Have you managed to resolve the problem? If so, what Was the solution? I'm having exactly the same issue with my Focus. It's done 140k miles. Dealer serviced since new. Had the DPF replaced, as well as the DPF pressure sensor - but to no avail. Turned out that when the garage refilled the additive tank, they didn't prime the system. So 65k miles with no additive...... But I'm now thinking that this has b*****ed more than just the DPF. The "independent" garage that I took it to in order to get the DPF replaced - they reckon that the turbo and the EGR valve are both OK. Right at the start of it all, I thought it was a fuel issue, and a few other forum posting suggested a possible injector problem.... Would certainly explain the poor mpg. Any suggestions would be appreciated.
Reply | Report as offensive | Link
Sat 27 Apr 2013 08:54
09 Ford Focus estate 1.6 TDCi Zetec 109bhp - Intermittent engine stutter - mlh681

Papa,

I experienced a sticking EGR valve a few months ago. My symptoms started out just as you describe, but were periodically a little more severe, with the added joys of sometimes stuttering/stalling when pulling away and occasionally a reduction in power (though not limp mode). It was an exciting couple of weeks.

In any case, I already had a 'D900' OBD reader (usually available online for £25-£30). In addition to showing live engine data this can store/clear fault codes and freeze-frame data after being disconnected from the vehicle, a feature that I find useful when taking our cars for repair.

Re: your suggestion that "No lights show on the dash so unlikely to show any fault codes..." - It probably depends; in my case the D900 did pick up an EGR fault code when I was having problems, although the MIL did not illuminate on the dash at any time:

I used the D900 to clear the fault code a few times to see if it came back (it did), although it just as soon disappeared of its own accord.

Finally - totally unrelated to your question, but hopefully of benefit to yourself and others with 100k+ Focus DPFs: when the DPF sensor hoses in my Focus began to fail at 105,000 miles, the Ford dealer would only sell me DPF hoses with a pressure sensor attached for £225+... my local independent was more than happy to sell me a set of suitable high-temperature hoses for under £10. Caveat Emptor.

Hope this helps, and Good Luck getting things sorted!

M

Edited by mlh681 on 27/04/2013 at 09:00

Reply | Report as offensive | Link
Sun 28 Apr 2013 17:39
09 Ford Focus estate 1.6 TDCi Zetec 109bhp - Intermittent engine stutter - dogdays

If its a stcking AGR you can do what the A A man did to my ford. Use a can of AGR cleaner and squirt it into the unit via its vac tube. You need to get someone try try and keep the RPM at around 1000 whilst squirting and use the whole can . This worked fine for two years on my 1800 Focus turbo diesel.I also use a Cetone based injector cleaner in the fuel system.

P. S Are you using supermarket fuel.

Reply | Report as offensive | Link
Mon 9 Sep 2013 18:29
09 Ford Focus estate 1.6 TDCi Zetec 109bhp - Intermittent engine stutter - Papa Lazarou

Sorry for the delay, I didn't receive a notification that there had been another reply.

Nope, I only use BP fuel and only ever fill the tank to full from empty as advised by more than one mechanic.

I did get engine management warning and reduced output but the fault registered was a blocked DPF.

New one fitted (not a nice job) but all seems well so far. No doubt at my cars mileage an EGR clean would be beneficial so it is on the list of maintenance things to do.

Thanks for your reply.

Papa

Reply | Report as offensive | Link
Mon 9 Sep 2013 18:56
09 Ford Focus estate 1.6 TDCi Zetec 109bhp - Intermittent engine stutter - Papa Lazarou

Thank you for your informative reply and apologies for my late response, no notification was received via email so sorry.

EGR valve is still suspect I guess but one other thing has come to light, may not be relevant but time will tell.

My main air intake at the turbo had also split, for reasons I won't bore you with I had to use OE parts (it is actually 3 hoses as they don't sell them individually) but it does include a plastic body and sensor (I think Air Flow Mass Meter?) but at the princely sum of £108 so yet again time will tell. My mechanic says that AFMM's tend to cost £50 to £70 each, whether or not that takes the sting out for others is a personal matter.

It seems to me that EGR valve is pretty much all that is left to cure the stutter should it reappear, fingers crossed it doesn't as I am thinking of selling the car as change in work makes a van more relevant. I will through my honest nature repair / replace it if necessary though.

Once again thanks for your help, maybe this can help others too, fingers crossed.

Papa

Reply | Report as offensive | Link
Tue 4 Mar 2014 14:50
09 Ford Focus estate 1.6 TDCi Zetec 109bhp - Intermittent engine stutter - Papa Lazarou

Ok, possibly this thread is dead but here goes.

Fault as described returned some time after DPF was fitted (improvement a coincidence?), then a new one!

On motorway whilst attempting to accelerate har dfrom about 70mph for overtake the engine just died, similar to engine braking is best way that I can describe it. As soon as it was stationary in the lay-by it started again without any problem and got me to my destination and home (200 miles) without stopping.

Since then it's had an EGR valve fitted, it is an aftermarket one 'Leder' or something along those lines (told they are a good version?) and it is no different. Seems to be loss of power through turbo cutting in and out maybe but to be safe it has had a new fuel filter fitted yesterday and again, no improvement.

Any fellow owners have any experience that might lead to the root of the problem?

Reply | Report as offensive | Link
Tue 25 Mar 2014 19:04
09 Ford Focus estate 1.6 TDCi Zetec 109bhp - Intermittent engine stutter - lfro16

Hiya

I purchased my 2009 1.6 TDCI zetec estate about 8 weeks ago and drove away very happy, 2 days ago the EML light has illuminated and I am now experiencing identical problems to you, intermittent power, flat spots, rev range seemingly with a mind of it's own and what seems like the worst turbo lag I have experienced, The car has full service history from main dealer and only has 68,000 miles on the clock, the car is under warranty so took it straight in to be looked at and the fault that showed on diagnostic was relating to EGR valve, that has now been replaced and 24 hours down the line here I am again with the same problem, car seems to pull when it wants to not when i put my foot down!!!!

have been told to give it a "proper run" and this should "clear everything out" sounds like a load of bull to me and i think the EGR is just the tip of the iceberg, the garage are taking it back in tomorrow so i will let you know if anything they do helps at all.

Reply | Report as offensive | Link
Tue 22 Apr 2014 17:36
09 Ford Focus estate 1.6 TDCi Zetec 109bhp - Intermittent engine stutter - Papa Lazarou

Hello there, only just seen your post.

How did you get on??????

I've done some more digging or rather a friend has on my behalf.

A diesel specialist in my area has been asked and says that he's come across similar on other diesels though not specifically this engine.

On one it was the EGR valve (mines been replaced without improvement though not a Ford part), I'm ignoring that as I have not had any fault codes show on the diagnostic machines before or since the part was changed.

Other one is the Turbo Actuator (some call it the Wastegate I believe???????) which has been on the list of possibilites so I'm going to change that next. Ford won't sell you one without the Turbo so non genuine part again I'm afraid. We've been thinking vacuum problem relating to turbo for a while now but have not found any leaks or dodgy looking pipes. We have changed the Turbo Boost solenoid on the rear of the engine block (smallish brown thing with 2 or 3 (depends on car) vacuum pipes on one end and a multi plug adaptor on the other.

No change again after fitting. but at least this guy has now given me something else to spend my hard earned cash on, fingers crossed.

This 'specialist' has basically said that driving thes cars for economy mpg is the major factor so to drive it a bit harder in future!!!!!

Apologies again, I don't get notifications that there has been a post and after a while I log on less and less often.

Reply | Report as offensive | Link
Wed 7 May 2014 18:08
09 Ford Focus estate 1.6 TDCi Zetec 109bhp - Intermittent engine stutter - Papa Lazarou

Wastegate / Actuator changed, no improvement.

Time to give it up as a bad job it seems.

Reply | Report as offensive | Link
Sun 12 Jul 2020 09:56
09 Ford Focus estate 1.6 TDCi Zetec 109bhp - Intermittent engine stutter - Stuart Horne
I know few years after you put this post up . Did you ever get to bottom of problem?
Reply | Report as offensive | Link
Sun 31 Jan 2021 15:23
09 Ford Focus estate 1.6 TDCi Zetec 109bhp - Intermittent engine stutter - Sw0rd0

Dirty camshaft position sensor , cleaned and worked on Mazda 3 with the same 1.6 engine

Reply | Report as offensive | Link

Looking for a garage you can trust? Honest John's Good Garage Guide has thousands of reader recommended garages, plus how-to guides and tips on servicing.

The Good Garage Guide