My Focus 2.0 TDCi had a problem in last spring where sometimes when you started the engine, it didn't quite reach idle and didn't respond to throttle inputs. The main dealer replaced the EGR valve but a month or so later, it did it again. The dealer said there was no fault codes and they couldn't reproduce the fault so nothing was done.
The car has been fine throughout the summer but over the past few weeks the problem has reappeared. Today it took about 8 attempts to get the engine running properly. I drove to my dealer and booked it in for investigation next week. As I got into the car at the dealer..... a lucky break. The engine didn't start correctly. The exhaust was belching out black smoke and it wouldn't respond to throttle.
I dashed back into the dealer and said, "quick, the fault is present now... get someone to have a look". The service receptionist said, sorry our diagnostic technician isn't here at the moment. I pointed to the other Ford technicians working in the workshop and she said they were not trained to operate the equipment. I said that it was important that someone witnessed the fault because I knew that it was unlikely to reproduce the fault when it is booked in next week.
The receptionist came out and witnessed the defect. I told her (politely) that I would not accept any "unable to reproduce fault" excuse when it goes in next week. She said that Ford will not authorise any part replacement without a fault code present. I tried to keep calm because the girl was quite young and I don't like to appear to be threatening but I tried to make it clear that my warranty conditions overrode Ford's instructions to its dealers.
I left feeling quite shocked that these modern, well paid vehicle technicians can't do anything without a fault code. I'm an aircraft engineer working on modern aircraft. As you can imagine, we make high use of built in test equipment and external diagnostic equipment but if the equipment fails to show up a fault and the pilot insists that there is a fault, we don't just give up. We go back to basics, troubleshoot on paper and start replacing bits.
Sorry, rant over. If Tim or anyone else has any idea what the problem is, I'm sure my dealer will be very appreciative :)