Touting this problem out there in the hope someone can throw some light on this long and sorry saga.

Many thanks.

Symptoms

No noticeable problems around town, problems appear on faster roads when in 5 th gear in the 40-60mph range. If I accelerate 40-60mph at a gentle pace don’t usually have a problem. If I put my foot down a bit more forcibly sometimes the car will slowly reach 60mph without the judder. Other times it will feel slow to accelerate, like there is some mysterious force holding the acceleration back, and eventually it will feel like there is a sudden release, the car will give a very noticeable judder and then the car will pick up speed.

Other times can be driving at 60mph flat bit of road, ease up momentarily as I come to traffic (no more than 1 second), foot depresses the accelerator and I get a serious of much smaller “flutters”. In these cases my foot doesn’t completely leave the accelerator, let alone move to the brake pedal.

Can very, very occasionally, in 50-60mph range get the small flutters without me consciously having had to ease off the accelerator, although it’s not to say there hasn’t been a small change in position in my right foot.

Problem appears to be intermittent, but it's possible I only see it as in intermittent problem because of my reserved driving style. It will do it in all temperatures and even at the end of an 80 mile motorway journey.

Driving style, very conservative, economy comes first, 55-60 mph on motorways, else the speed limit at all other times. Say 8,000 annual mileage, split between say 2,000 urban, 3,000 out of town roads, 3,000 motorways\trunk roads.

Problem History

1 st May 2010 Purchased car, odometer reading 24,500, ran it happily on supermarket diesels for just under 2 years for additional 14,300 miles.

17th Feb 2012 Car had 10-15 miles of fuel left in the tank. I filled up with Diesel and drove about 500 yards, when the car started juddering at 20mph on a roundabout and the “Engine Malfunction” light was lit. I called the AA out, but they could find nothing wrong with the car, and could not even see the original error message in my cars computer logs. The car did stutter several times, for 1-2 seconds each time, for a few months after, but no more error messages.

5th May 2013 I had driven about 40 miles, was doing 60 mph on a straight and flat piece of the A12, when the car started juddering again, the “Engine Malfunction” light was lit and the ESP light came on as well. Called the AA out again, again they could find nothing wrong. I completed my journey that day, about another 40 miles on the A12\M25, it stuttered a couple of times for 1-2 seconds each time, but no more warning errors.

2 nd June 2013 Took the car to Ford garage, no errors found in cars computer logs. Engine management firmware upgraded.

9 th August 2013 Filled up with Diesel, and started my 2 week holiday to Bournemouth the following morning, car very juddery from the start, 25 miles into my journey, lots of judder, engine malfunction and ESP light lit again and reduced power. Pulled over & restarted engine, started off again, but 1 mile further down the A12 same thing so called the AA. This time AA bypassed EGR valve and followed me for 5 miles still a couple of intermittent judders. So AA replaced air temp boost charge sensor about 1 hour later and removed their bypass plate to EGR valve. Car seemed to be ok after this, although not holy convinced as still had very occasional judders. Continued on to Bournemouth. I have always used Tesco Diesel, but whilst on holiday I put about 60 Litres of BP Ultimate in the tank to see if this would help, but whilst still on holiday…

21 st August 2013 car very juddery from the start of a 20 mile journey. Both Engine Malfunction and ESP lights illuminated again and into limp home mode for last quarter mile of journey. Unable to get car above 15-20mph. Parked the car, no increase in engine noise when pressing accelerator pedal to the floor, no unusual smoke from exhaust. Left car for 5 hours, came back to start the 20 mile return journey, juddery from outset, lights came on again after about 3-5 miles and limp home mode. Parked car, restarted engine after 2 mins and managed to drive remaining 15 miles.

22 nd August 2013 returned from Bournemouth - 190 miles, no error lights came on, but small intermittent judders every 5 miles or so. Kept car to 45-50mph all the way home as felt I didn’t want to push it.

11 th September 2013 took to Ford garage; they found error codes in the cars computer pointing to injector wiring loom & 2 of the injectors. Replaced wiring loom and Diesel fuel filter and annual service\MOT. Odometer reading now 51,700.

1 st November 2013 2 injectors replaced by Diesel engine specialist. The last 1,300+ miles have been run using BP or BP Ultimate Diesel rather than supermarket fuels in my own attempt to flush out any potential problems. Car still exhibits same symptoms.