it may well be low 32K that's part of problem with never really getting hot

 

I can't vouch for how it was driven for the 1st 22k miles, but I've had it for 10 months and have done 10k miles, roughly doing a 25 mile journey each way to work. The problem is 70mph in 5th is only running the engine at 2100rpm. The odd thing was I pushed it a bit coming home Friday and that must have been what started it. This was with the sole purpose of getting the engine/exhaust hot. Still only sitting between 2500 and 3000 rpm.

I'll see what happens today.

 

Something I've just found

P1402 FORD

P1402 FORD - EGR Metering Orifice Restricted


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Possible causes
- Damaged Engine Gas Recirculation (EGR) sensor
- Damaged Engine Gas Recirculation (EGR) valve.
- Engine Gas Recirculation (EGR) sensor harness is open or shorted
- Engine Gas Recirculation (EGR) sensor poor electrical connection
- Damaged powertrain control module (PCM)
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Symptoms
- Engine Light ON (or Service Engine Soon Warning Light)
P1402 FORD Description
Diagnostic trouble code (DTC) P1402 indicates a malfunction in the Engine Gas Recirculation (EGR) valve position (EVP) sensor circuit.
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Read more: OBDII Code P1402 FORD - EGR Metering Orifice Restricted | HelpForCars.net

 

Thanks Richard. That was one I came across when Googling.

I've spoken to my warranty people and they asked me to book it in for a diagnostic check. This will then be given to one of their asessors to review. The problem is, I took it really easy going to work today, keeping it below 2k rpm, occasionally going to 2.5k rpm, and the fault has cleared due to not pushing it!! I want to make sure it goes to the diagnostic check with the error stored in the ECU on Friday. Otherwise I'll be wasting £50+.

 

If it's due to a faulty EGR detection circuit then it could be there or not there whatever
#
You might think to ask when they do the diagnosis check if they are going to include for broken wires or grubby connections to the PCM which can give some funny problems

 

The Ford dealer, Busseys - Dereham, ran the diagnostics and it came back with the EGR fault. The fix was a software update which changed the parameters for this fault. Very pleased because they didn't charge me for the diagnostics or the software update, and booted it home and the P1402 error never re-occured! Not counting my chickens just yet......

 

After two weeks, the P1402 error came back ( I've been waiting for it as it still drives the same. All they did was put a software update on that changed the trigger value, so whatever the problem is with the EGR, it's getting worse. I can now hear the open/close cycle of the EGR valve when I turn the engine off, approx 10 times.

It's booked in for a diagnostic check next Monday, and they'll pass the report onto Warranty Direct. Fingers cross all will go through ok.

I'm sure cars know when you want to sell/part-ex them. I was looking for Focus Zetec-S 2.0 TDCi (Sports Pack) which I originally wanted, but ended up with the C-Max, and then the error comes up!

 

If you can hear the valve moving then that part of process may well be OK
The other fault that has come up a couple of times recently that gives fault codes but it purely mechanical has been blocking of the holes in the EGR cooler (just upstream of the valve itself)

 

My local Ford dealership has ran the diagnostics and confirmed the EGR fault. One of Warranty Direct's exclusions is carbon build up. Even though I've paid the extra on the policy for the optional cover, which covers emissions, and specifically lists the EGR valve, I'm not covered. Have I got a leg to stand on to take this further? The cars a 2008 and only done 32850 miles. Would an EGR valve carbon up in that short mileage?