Gas Recirculation Valve (egr Valve) problems of the 2002 Ford Focus

Exhaust gas return (egr) line failed at exhaust manifold mounting flang . This failure allows carbon monoxide and carbon dioxide to seep into the passenger compartment of the Focus. Co poising can cause: 1)death a) the driver of the Ford Focus passes out and dies in a crash b) the driver of the Ford Focus dies from CO poising 2)organ failure it is interesting to note that you can't attach a photomicrograph's to this complaint form?.

The day was very hot, 90+ degrees. I had the air conditioning on while driving and had to take my husband to a dentist appointment. I left the car running with the air conditioning on for about 10 minutes, then shut the car off. After another 5 minutes, I restarted the car, with air conditoning on and waited for my husband to return. The car was running for a total of about 25 mintues while parked. My husband returned and we proceded to go over to the other side of town to get some dinner. It was 4:30 pm at this time. On our way, the car started to 'jerk' forward and backward and I had no acceleration at all. I stepped on the gas and absolutely nothing happened. I managed to get over to the side of the road when the engine just died. I tried to start it several times to no avail. We waited several minutes and I was able to restart the car. We drove on, with the air conditioner on for about 6 more miles when the same thing happened. I managed to get off the road, but not before the engine died. My husband called a local Ford dealership and told them what had happened and we were told it sounded like the fuel pump might need replacing. We had the car towed to a local Ford dealership, not the one we had called, and were told they would get to it that night yet. They called us at 8:30 pm and had not gotten around to doing the diagnostics as yet. They called back within 30 minutes and told us that the fuel pump will probably need replacing, but they will call us as soon as they knew for sure. At 11:30 pm, they called to say that the diagnostics had shown nothing and they could not replicate the problem. They had no idea what the cause may have been and were shocked that such a thing could even happen to such a new car. There was nothing they could do. We picked the car up this morning and are praying to god that we can get home this evening without the problem happening again.

I was driving on the on-ramp of the PA turnpike when scalding water from up under the dash poured out onto my right foot. I was barely able to drive the car to a safe stop. I sustained second and third degree burns to my right foot. The wrecker took the car to a Ford dealer in emmaus, PA for repairs. The service department originally told me that the evaporator line was plugged, but when I picked up my car, the narrative on the service form said that the line was not plugged. They replaced the evaporator which I understand entailed removing the entire dash. I do not know if the old part is available.

Heat shield dropped while driving on west ridge road causing sparks. It ruptured the fuel line which caused the fuel to spew all over the road. 911 contacted, road closed and taco bell where the vehicle was moved, was evacuated due to the massive fuel leak and fumes. Dealership contacted, tow truck picked up vehicle.

At least twice a week my car takes 2-5 tries to start. After it starts, it runs very rough and feels like it's going to stall. . . Sometimes it does if I'm at a light. I have a stick shift and there's no indication on the idle that it's running low. My car has been in the shop more than I've had it for the last six months. Ford tells me they haven't received any complaints like this and the dealership has told Ford they can't replicate the problem. . . Even though they've told me on a couple of occasions that they have. Usually they don't replace anything but so far they've replaced my egr valve, fuel pump, and gas tank. The dealership has been inconsistent on how they document the time my car's been in the shop and with a one year old and a four year old. . . I can no longer take time to go to the shop. . . Not to mention lossed time at work. I actually like my car but I need it to start and they obviously can't fix it. This has been a frustrating experience and we will no longer purchase Ford vehicles because of the lack of cooperation from both the dealership and Ford. We've bought an f-150, explorer, and the Focus from the same dealership. . . I guess our money was just a drop in the bucket for them and in the long run customer don't really matter. I don't know what to do about the car except to try for the lemon law. . . But since the dealership has chosen to lie and say they can't replicate the problem, who knows how that will turn out.