Ford Focus Zetec 2002 1.6 petrol - caughing & splutering at low revs. Plus amber engine management warning light comes on intermitantly. I've changed spark plugs and set correct gaps from owners manual. Problems still there, Please help!!!

Jon Ellis., October 2008

this happened to my focus zetec cleaned valve with carb cleaner and this solved problem first time been runninig fine know for 3 months

sandy, August 2010

Thanks Steve, got some further advice from a mate who is a mechanic, he said change coil pack & HT leads as these 2 items tend to break down over time with moisture ingress.
So, i've changed 4 HT leads & coil pack.......and problem is sorted!!!
Thanks 4 good advice, hope this helps others with same symtons.

Jon Ellis, October 2008

Hello Jon,sounds very much like your coil pack has gone,seek one out from an auto factors,four bolts and a plug in lead job done.

steve, October 2008

Hello Jon,

Exhaust Gas Recirculation system is used to lower NOx (Nitrogen Oxides) caused by high combustion temperatures. The EGR valve recirculates a small amount of exhaust gases into the intake manifold, this lowers the temperature of combustion, which reduces the formation of NOx compounds, part of emission control.
When EGR is not functioning as it should, the engine will give the same symptoms as loss of vacuum, which relates to loss of power.
Usually EGR is located within sight from top side of engine. My experience--facing front of vehicle-look toward left side rear engine compartment. Somewhere in that area and connected in some manner to topside exhaust system. As I advised in previous post--remove, clean first, be sure gasket is intact any leaks can cause problems.
Hope this helps

In Christ,

Walt, October 2008

Thanks for advice Walt, however 2 things :-

1. Car has done 40,000 miles in 6 years. (not a huge amount of miles)

2. Can you give me some further detail on the 'EGR' valve (what does EGR stand for ?) Where is it's location on the engine, any special advice would be greatly appreciated.

Thanks, Jon.

Jon Ellis, October 2008

Hello Jon,

If your vehicle has a lot of miles on it, it could be the EGR valve, not opening and closing properly. Over time carbon builts up internally,some models have a diaphragm in them and works up and down on a shaft inside the unit, I've cleaned this in the past, remove and disassemble (usually not complicated to do), and either clean gasket and/or replace it. Other systems. have only a solenoid or two, which can also become restricted with carbon. This is worth a check, you stated that it was coughing and spuddering at low revs--EGR problems can have your symptoms as well as lack of power, if EGR is not working correctly it can be either symptom.
EGRs can set computer codes also, if you have access to a Code Reader this may help also.

Hope this helps,

In Christ,

Walt, October 2008